We had celebrated Halloween 2016 with our friends in Yokohama. Little T was dressed as BB-8. I had only a week’s time to make the costume. For BB-8’s body, I used the same technique that I used to make angry bird costume.

Materials Required for Headpiece:

1. Felt fabric
   • White
   • Orange
   • Grey
   • Black
2. Baseball cap
3. Glue gun / Fabric glue
4. Acrylic colour
5. Thin straw
6. Toothpick
7. Capsule cap from the capsule toy / Styrofoam ball (for the black optical lens)
8. Silver glitter pen

Materials Required for Body:

1. Felt fabric
   • White
   • Orange
   • Grey
   • Black
2. Filler material
3. Glue gun / Fabric glue
4. T-shirt for outline
5. Pencil & Chart paper
6. Sewing needle and thread (White)
7. Scissors
8. Black marker

Procedure for making the headpiece:

Cut the white felt in the shapes of the front, side and back panel of the cap.

My cap’s brim is grey in colour so I didn’t use felt there. If the brim was of some other colour, I would have used grey/white felt to cover it up.

Use fabric glue/glue gun to stick the felt to the cap.

For the black optical lens of BB-8, I used the transparent cap of capsule toy and painted it black. You can also cut the styrofoam ball into half, paint it black and stick it on the cap. I have used silver glitter pen to draw a thick outline on the base of the optical lens.

Use white acrylic to paint the straw and toothpick. Both ends of the straw must be painted black.

Glue the straw and toothpick on the top of the cap. Glue gun works better here.

Cut the orange and grey felt patterns for the headpiece. Glue them on the cap.

 

Procedure for making the body:

Please refer to the below link:

Angry Bird Costume

The procedure is the same as the one for making the body of the angry bird costume.

Instead of the angry bird pattern, cut the pattern for BB-8 using orange and grey felt. I’ve used a black marker pen to draw the outlines.

Note: Its easier to glue the BB-8 pattern on the front side before filling the filler material.

Unlike the angry bird costume, for BB-8, I’ve used elastic on both sides to keep them together.