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DIY Astronaut Costume – Halloween Hacks

An easy DIY astronaut costume with instructions on how to sew a hood and add a few patches!

How to make a comfy DIY astronaut costume from non-costume PDF patterns that you might already own! Someone was unable to complete their post for Halloween Hacks on short notice so I whipped up a hack of my own from two of my favorite patterns, and sheet/t-shirt upcycle scraps. There’s a tutorial for making the “helmet” at the bottom of the post.

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I already used the Greenstyle Balaclava pattern* to make a DIY ewok hood and it was my first choice for a quick costume hack. The NASA patches are a trio from Amazon* and the shirt is the Recess Raglan from See Kate Sew. I used a mash of jersey sheet & upcyled shirts for the white pieces and then grey ribbing for the binding, white ribbing for the shirt’s cuffs/binding.

This is the size medium/small hood (3t shirt) cut at the shortest length. I probably could’ve cut it even shorter, once I added the binding it stiffened up a little which I didn’t anticipate.

I’ve mentioned taking a DSLR class and trying to play with my settings more, clearly it was not working in my favor for this project. A view of the back, which is nicely contoured.

I am happy with how it came out! Since he doesn’t “get” Halloween yet I’m not particularly inclined to put a ton of time into something he will only wear once so I love that the shirt is totally wearable and the hood can be a dress-up accessory. I hand-stitched the patches on so they’ll be easily removed and reused as he grows.

I’m thinking if I have time I will make a cape with a jetpack applique – I know he wouldn’t keep a “real” jetpack backpack on!

Get ready to click around and be inspired! I rounded up last week’s looks in this post and there is more to come:

Blog Tour!

Wednesday, October 1st: Rebekah Sews & Dog Under My Desk

Thursday, October 2nd: Friends Stitched Together & Sew Pandi

Friday, October 3rd: That’s What She Crafted & Everything Your Mama Made & More

Monday, October 6th: Shawnta Sews & Handmade Boy

Tuesday, October 7th: Muse of the Morning & Swoodson Says

Wednesday, October 8th: Call Ajaire & Sew McCool

Thursday, October 9th: Once Upon A Sewing Machine  & imagine gnats

Friday, October 10th: The Sewing Geek & Feather’s Flights

Monday, October 13th: Get Your Crap Together & Needle and Ted

Tuesday, October 14th: The Shaffer Sisters & The Inspired Wren

Wednesday, October 15th: Pattern Revolution & Just Joshin

Tutorial for DIY Astronaut Hood


  • Greenstyle Balaclava pattern*
  • 2 pieces of grey ribbing with the stretch going horizontally: 2.25″ tall X 17 inches long & 2.25″ tall X 20 inches long
  • 4 matching pairs of the balaclava cut out from white knit
  • NASA patch*
  • Iron

I used a 3/8 seam allowance throughout.

1. Cut all materials

2. Press both bindings in half, lengthwise (like a hot-dog), and then flatten out and place right sides together (RST), sew short ends together.

3. Fold back and press again, wrong sides together (WST).

4. For both pairs, put RST and sew along the long curved edge and the short throat edge leaving the eye/face gap raw.

5. Turn one hood right side out and slip it over the other hood, aligning all the edges and seams. This place all the sewn seams on the inside, facing each other. I topstitched along the seams once the two pieces were aligned but that’s optional.

6. Baste around the face edge, catching both layers.

7. Stretch the smaller binding and pin or clip around, with the raw edges facing OUT so you can see them when the hood is right side out.

8. Press the seam allowance outwards.

9. Baste the seam allowance down.

10. Fold the binding piece inwards, stretching it to cover the seam allowance. Pin around and press if desired.

11. Sew the binding down.

12. Admire your handiwork and then repeat steps 6-12 with the longer piece of binding and the neckline opening.

You’re done! Admire your soft, enclosed seam NASA hood after hand-stitching the patch on to the forehead.

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This Post Has 17 Comments
  1. CLEVER & CREATIVE: I agree with both comments . . SUPER idea, a “helmet” (balaclava) for your little son’s Trick ‘n’ Treating costume. Detailed tutorial for the astronaut hood (with authentic NASA embroidered patches) to add to T-shirt & helmet. 12 EASY steps and VIOLA . . . done and ready to wear to a Halloween party, pre-school party or walking to neighbors’ houses. I like your use of up-cycled white knit & the grey ribbing is ideal for the trims. THANKS for sharing. Sarah in Minneapolis

  2. Love this! Being in Texas I did not think I had any use for the Balaclava pattern. We do a ton of dress up outfits though. I’m going to have to get it now!

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