Star Wars Ewok Costume

I made a fighter pilot and Ewok costumes for the kids the past Halloween. At the local Comic convention the Star Wars team told me the Ewok was potentially good enough to be certified. I did not go through that process though the compliment made me very proud and so here we are posting my first ever Instructable!

The costume is based largely on the McCall's pattern number 8731. The pattern offers great instructions for the hood and jump suite. However, the face mask lacked any shape and the hands and feet remained exposed. I used the pattern as my base but incorporated a full face mask with EVA foam along with hands and feet. Hope you enjoy the project as much as we did!

McCalls Sewing Pattern 8731

3.5 yards of fake fur fabric of 60" wide standard bolt fabric

4.25" fake suede 45" wide standard bolt fabric

1 large 45" zipper

1 yard of 5mm EVA foam

Contact cement

EVA foam clay

1 sheet window tint film 8"x11"

Brown acrylic paint

White acrylic paint

Yellow acrylic paint

1 pair of slippers

1 long wooden stick of staff

Optional 1 dry leaf and clear duck tape.

sewing clips

Brown thread

thin leather cord

Optional Bag:

1/4 yard of fabric

2" D rings quantity 2

Optional 1/4" grommets quantity 2

Optional thick leather cord

The first thing we will make is the EVA foam mask. This is the hardest part but it is the most critical. First cut out all of the templates for the face mask from the pattern. Trace and label everything on the EVA foam.

Cut out all of the pieces and assemble as in the photo using sewing clips and contact cement to hold the mask together. Once the mask is assembled allow it to completely dry. Do not worry if you have gaps in the foam. This will be covered with fur and will hide any imperfections.

Using EVA foam clay shape the nose and mouth. Note this clay will expand some when drying so it will puff up. Set the pieces off to the side to dry over night.

Use the face mask pattern again to cut out all of the pieces of fur fabric. Follow the directions in the pattern to assemble the fabric face mask. You do not need to attach the back of the face mask so skip that part. We will be making a hood, and the back of the head will never be seen. Not doing this portion helps keep the back of your head open and cooler.

Once the face mask is sewn and the foam mask is dry, stretch the fabric mask over the foam. Use contact cement to glue the fabric to the foam. Especially push through the trim around the eyes, mouth and glue the fabric to the inside of the mask.

Use acrylic paint to paint the nose and mouth. Once dry, glue them in place with contact cement.

Cut out 3"x3" square black film. Use a heat gun or blow drier on high heat to shape film into bulging eyes. Push the film through the back of the mask out. Secure the film from the back with contact cement. Once dry, use EVA foam clay to cover the rough edges and make a smooth surface. Allow to dry over night.

You now have the base mask done!

Sew the hood per the McCall pattern instructions. Use the thin leather cord to hand sew the criss-cross pattern along the entire seam length. Cut out the ears from fur fabric and the EVA foam. Sew the ears and turn them right side out. Insert the foam into the ear "pocket" and attach the ears directly to the hood. This is helpful in the event you do not want to always wear the mask. You may choose to only wear the hood.

Once you have attached the ears your mask is 100% done!

For the feet use old slippers and apply EVA foam clay to shape the toes. Allow them to dry over night then paint them using acrylic paint. For the hands, trace your hand out with 1/2" margin as a mitten. No need to focus on the details of fingers we just need a mitten shape. Use that as the sewing pattern and cut out the top of the mitten in fur fabric and the bottom in the fake suede. Sew the two sides together and turn them right side out creating a rough mitten for each hand. No need to trim the edges again these will be covered with the sleeves and the fur will blend in together.

Sew the jump suite according to the instructions. Do not trim the edges again, leaving them rough will allow for the fur to blend in around the feet and wrists. Instead of ties for the back of the jump suite I added a large zipper on the inside. I purposely installed it "backwards", such that the pull is hidden. I also added trim around the neck for comfort.

Find a large stick for a staff. The rougher out door kind works better. I found a flat dry leaf and pressed it between two pieces of clear duck tape. Then taped the single leaf to the stick creating a rough staff for my Ewok to use. I also used the spare suede fabric to make a cross body bag. I used a simple pull tie closure with two D rings to make the sling length adjustable.