Coolest Adult Cast Away Couple Costume

My girlfriend and I decided to mix up our usual Halloween ritual of being different types of food items and went with Tom Hank’s character and Wilson from our favorite movie “Cast Away.” Needless to say the costume was a huge hit, although everyone wanted to take more pictures with Wilson.

The Wilson costume was much more time consuming to make.  We started by getting a 4-foot beach ball and then paper mached many layers on it, leaving holes for the head and arms.  At first I was nervous it wasn’t going to work, so I wound up putting so  many layers on it that she could have gotten hit by a car and just rolled down the street it was so solid.  Anyway, after the paper machete hardened we spray painted the whole thing white, then spraypainted the Wilson face in a dark red color, with a dot of black for the air hole nose.  She wore white leggins and shirt, along with a Wilson head band with pieces of Palm sticking out to complete the Wilson look.

For the Tom Hanks character I basically just got a long beard and wig combo and used a cut up sheet for my bottom covering.  I got a Fedex box and long stick to complete the look.  I also tried to lose a few lbs after I knew what we were being to complete the look!

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    • maedchen

      I absolutely love this costume.  We are going to use your idea for our Halloween party Oct 13! It took some convincing to get my husband to go shirtless, but he’s going to do it!

      • Carm_jacobs

        How many layers did u put on the beach ball?

        • John C

          Hi Carm, I really wasn’t sure if it would work so I did a lot of layers. Probably at least 10 layers and I used computer paper for the top layer because I thought the paint would cover better on it.

      • maedchen

        Okay, I’m trying to finish this costume for Saturday and I was not prepared for how time-consuming the Wilson costume is!  You are so great for doing this!  I’m not giving up.  I hope it turns out as good as yours!  We are considering adding a pair of ice skates for him to wear around his neck (the scene when Hanks pulls his tooth out with it)–at least for the pictures.

        • John C

          Thanks! It was time consuming, I did many layers because I didn’t think it would really work.  By the end I think she could have gotten hit by a car and rolled down the street that’s how solid it was.  The skates are a great idea. I also had a wooden spear that I used for some pics. Good luck I’m sure you will be the hit of your party!

    • Candice P.

      This is such a good idea! So creative, yet simple! Awesome!


    A Few Days Adult/Teen Cost: $20-$50 Couple / Duo Costume