Awesome Little Big Planet’s Sackboy Halloween Costume

When my four year old son, Jet decided he wanted to Sackboy this year my husband was all sort of excited to make his costume.  The cool thing about this was once the Sackboy was made he could then dress that up in any costume he wanted as in the video game you go around and collect pieces to different costumes for Sackboy, however he ended up only wanting a cape!

We started with a top hat for the head, and used Great Stuff foam to build it up, then carved it to the shape we wanted, and then carved out the mouth.  The eyes are clear plastic Christmas ornaments from Micheals (there are advantages to all the Christmas stuff out before Halloween) cut in half and spray painted black.  We cut and hot glued them and the felt in for the mouth.  The head set a little low on Jet’s head so we put a little pillow stuffing in the top of the original top hat and held it up there with a piece of felt (hot glued), this also made it very comfortable to wear, and using the foam made it light weight.

For the body we bought a a roll of burlap, rolled it out on the floor and had Jet lay on it, then cut around him (a bit bigger of course).  Layed that down and cut another piece the same size (front and back).  We then sewed the front and back together with shoe string.  For the zipper, it’s also all made out of foam insulation, we used the thin silver sheets, spray painted the black part and just cut rectangles all the way up.  For the ‘handle’ part of the zipper we used the Great Stuff and carved it out, then spray painted it with chrome spray paint, be careful doing this as spray paint will eat though your foam.

This costume was a HUGE HIT! Everyone loved it and Jet loved all the attention. Although a lot of people didn’t know what he was they thought it was really cool anyway.  He wore this from 1:30 in the afternoon when his school party started until 7:30 at night and was very comfortable.  We live in Michigan, and Halloween is always cold and rainy so I think he was also the warmest kid in the neighbor hood. I did have to laugh though when he was running from house to house and tripped, his head went rolling haha. We had a lot of fun with this costume!

Thanks for looking!

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    • grateful

      Thanks so much for posting this!!!! Your son’s costume was perfect! My son has wanted to be sackboy forever and I thought making one that actually looked correct would be way out of my league. Your instructions have given me the confidence to try! My son is going to be thrilled!

      • JP

        Thank you! I hope it turned out! :)

    • Heta

      Wow, you have done a fabulous job! I am hoping to emulate this for my son’s costume this year. Did you use any other support or frame for the headpiece besides the top hat? How did you shape the lower half of the head (below the hat rim level)? Did you create a tunnel/opening below the top hat so that your son could slide his head in and out easily, and if so, what did you use to make the opening? (Or did you just carve a pathway out of the foam?) So many questions! Of all the Sack Boy costumes I have researched, yours is the best. I am super impressed.

      • JP

        Thank you so much!! I know its a year later but I just randomly came back to it as it popped up on my pinterest today. We used no other support or frame…When we were done with the Great Stuff it looked like one big blob and we started carving away. :)

    • Ashley Hobbs

      Amazing job! Also interested in more details on how you did the bottom portion of the head. Going to have to start soon to get it done by Halloween :P Or, if you’d be interested in selling it, I would totally buy it! ;)

      • JP

        Thank you!! :) I was going to try to sell it but Jet wanted to keep the head in this room as decoration, and its still in there today lol As for the bottom of the head we had to carve it all out. I know this is WAY after Halloween, I hope yours turned out!

    • Nubie

      I am trying to make this costume. I bought a hat to use as the base of the head, but I don’t understand how to do the bottom part. Is there anyone who can advise me?

    • crmsnglry

      Love the Sackboy costume. I am looking for someone who can custom make a decent looking Sackboy (LittleBigPlanet) costume. Wondering if you are willing to make another one exactly like the one you have, including the head for a 6 yr boy? If you are interested, please respond and we can work out the proper fit and compensation details. Thank you.

    • Jonna murdock

      Hahaha! Girls, we just have to accept this mom is a God among mere mortals!!!
      I have worked on this for several weeks. It, in no way whatsoever, will ever look like this costume. I have used 5-6 bottles of that sticky sh–stuff. I am mostly using my pinkies because my thumb and point finger have been stuck together for a week. Every crack in my house has gap filler in it because there is no use a little, come back after it dries, squirt a little more, let it dry, etc. Use it or lose it! BUT don’t pile it on your project or it will stay condensed like iron silly string. My son will need neck strengthening exercises to wear this burlap wrapped cinder block if I can salvage any part of this epic fail.
      I started reading comments hoping to understand the bottom part of the head but others are as lost as I am.
      This is not my first fail, unfortunately. About 80% of my pinterest projects end in failure. So this is in no way a slight towards you. Just wanted you to know that you are amazing, my friend! Absolutely amazing.

    • Craig Holland

      Wish you guys could make my little guy a costume like that. He loves Sack Boy. (Hint, Hint)


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