Epic Thomas The Train Halloween Costume

This epic Thomas the Train costume started out as a train for my two year old nephew for Halloween turned into an obsession for a 48 year old “child”. I started with a shipping container for the cylinder body. I then formed the face out of clay on an old fan base and wire mesh screen. I molded the clay in plaster, then in liquid rubber.

I poured rubber onto cylinder to attach it to the face. Most of the rest is plywood of different thicknesses. Except for the stacks and whistles, which are PVC pipe and old radiator steam valves. The weeks don’t turn because I was running out of time, but it does move very easily on large caster wheels. It is very large as you can see against my full size van. No blue prints of any kind where used, just a lot of staring, guessing and sleepless nights.

Can’t wait till next year!

  • Costume Ideas Brainstormer
    • Andrew

      My twins boys would love this. If you are interested in selling let me know.

      Thank you,


    Child Cost: Over $100 Individual Man/Boy Costume More Than a Month