So last year when my brother Lukus (8 years old then) watched 'Trick 'r Treat' he changed his mind about being the Grim Reaper for Halloween and wanted to go as "Sam". It was a little late and I promised him we'd do it this year. I kept putting it off and putting it off... I almost dropped the ball- Started on Thursday morning, October 28th and finished at 3:45pm on Sunday, October 31st. (Nothing like cutting it down to the wire...)
I would like to give praise to Bigturc's thread: http://www.therpf.com/f24/sam-trick-r-treat-72402/
While I constructed my brothers costume very differently, his thread was an invaluable resource throughout my build.
We started with a sleeper type suit. I used the standard McCall's animal jumpsuit pattern. I didn't use polar fleece, I opted for a terry cloth towel-like fabric. I think it looks good.
The feet aren't sewn on, they are only shoe covers. I would've liked to have done the full on screen accurate "footy pajamas" but this was just a better fit for us. This costume was to be used to trick or treat in and he did alot of walking...
For the hands, I just sewed a sort of Burlap sleeve and cut a hole for his thumb. Once he squeezed it on his hand I tied some string/yarn arond his wrist. (On Halloween I colored his fingers with a red permanent marker so he'd have "bloody fingers" but he hated it and wouldn't do it again for these pics- )
Now the costume has a helmet for shape (Sam has a pumpkin head) that I very crudely made from two candy bowls. I was going to cut vents all throughout the bowl to keep it cooler and perhaps let some air get inside the burlap sack/mask but the plastic bowls proved far too brittle for that. I ended up just cutting one large opening and reinforcing with duck tape. I also added a bit of padding to the top to make the flat-bottom of the bowl round.
You can see the padding inside made from bubblewrap and ducktape to help it sit on his head. It still wobbled a bit but he didn't want chin straps... (Which I wanted to add )
Throw the bag over his head (The hand stitching on this thing was SUCH a pain! I watched half a season of Breaking Bad while doing this alone!) and tie it at the neck with a length of rope and woolah!
He told me there was no need for eye holes, that he could see "perfectly"... until night hit. It was so funny watching him feel around with his foot for the edge of the steps. He was fine once he got to the porch with the light on. I ended up holding his hand and leading him around most of the night but he was having a blast! The look in his eyes when he looks at pics of himself is what makes everything worth it!