How to Make a Thomas the Train Costume

If you have a little one who would like to be Thomas the Train for Halloween, but you really don't want to spend all that money on a store bought costume, here is the solution. You can make an adorable Thomas the Train costume and you don't even need to know how to sew.

Difficulty: Moderately Easy

Instructions

Things You'll Need:

• Thomas the Train pillow panel
• Fabric batting
• Iron-on adhesive hem
• Scissors
• Train engineers hat
• Red bandanna
• Train whistle
• Thomas the Train candy bucket
• Straight pins
• Iron

1. Purchase a Thomas the Train pillow panel (see Resources). This can be purchased at most fabric stores. This panel actually contains two different images of Thomas so you can decide which one you would like to use. Cut out all four squares, keeping in mind that two of the squares will not be seen because they will serve as the inside of the costume.

2. Place the two squares you cut out on top of each other with the images facing each other. Measure approximately 1/2 inch to 3/4 of an inch in and use straight pins to pin around the top and side edges. The bottom of the square, which corresponds to the bottom of the train, should be left open.

3. Cut off a strip of iron-on adhesive hem that is the same length as the top of the square and place it at the top between the two squares, between the edge of the square and the straight pins. Use a hot iron over this area to adhere the two square pieces of fabric at the top. Be sure to follow the directions on the iron-on adhesive hem package in regards to temperature and time. Repeat this step for the two sides of the square.

4. Cut a piece of square fabric batting to fit inside of the fabric square. In order for the batting to fit inside, it needs to be approximately 1/2 inch shorter than the fabric squares on each side. Place the square batting inside the fabric square to be sure it fits. Then remove the fabric batting.

5. Measure approximately 1/2 to 3/4 of an inch from the bottom and use straight pins to pin aross the bottom of the squares.

6. Partially seam the bottom of the squares. Measure the length of the bottom and subtract 3 inches from it. You will leave about 3 inches of space in the middle of the bottom seam open to put the batting into once you turn the squares right side out. Take that measurement and divide it by two. Cut two pieces of iron-on adhesive to match that length. Place it at the bottom between the two squares, between the edge of the square and the straight pins. Use the iron to apply heat to these two sections and form a seam.

7. Turn the square right side out. Be sure to poke the corners out so they form 90 degree angles. Insert the batting through the 3-inch hole at the bottom and make sure it fits nicely with no lumps. Fold the edges of the 3-inch hole in, place a strip of iron on adhesive in between them and close the seam by ironing.

8. Repeat Steps 1 through 7 to form a second fabric square. One will be the front of the Thomas the Train costume and the other the back of the costume.

9. Use the border from the Thomas the Train pillow panel to make two shoulder straps. The length of each strap will depend on the height of your child. Once you determine the correct length and cut accordingly, use the iron on adhesive to seam the edges. Then use the iron-on adhesive to attach the shoulder straps to the front and back of the costume.

10. 
     

    Choose clothes to be worn underneath. This Thomas the Train costume allows your child to wear just about any clothing underneath, depending on the climate. Be sure to accessorize with a train engineer's hat, red bandanna tied at the neck, train whistle and Thomas the Train candy bucket.

Resources

• Picture of Thomas the Train Pillow Panel