How to Make a Zorro Costume

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Making a Zorro Halloween costume is an easy and fun project. Now that Halloween is approaching, it is time to start thinking about how to turn the average Joe into a dashing Spanish Robin Hood, or you can create a female Zorro costume. All it takes are some basic supplies and a little imagination.


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Things You'll Need

  • Black trousers

  • Black shirt

  • Black fabric

  • Black ribbon

  • Sewing machine or needle

  • Red fabric or red scarf

  • Scissors

  • Chalk

  • Black gloves

  • Black hat

  • Mask

  • Black boots

  • Black thread

  • Black eyeliner

  • Play sword

Step 1: Get Your Zorro Costume Pants and Shirt

Find or buy a pair of black trousers and a black long-sleeved shirt. Go online and buy a black Renaissance shirt. This is a shirt that has no buttons; a V neckline and collar; and full sleeves, like a pirate's shirt, with cuffs.


Step 2: Make a Zorro Cape

Make a black cape for your Zorro costume by taking about 2 1/2 yards of black material (for an adult) and sewing a black ribbon across one end. Drape it across the shoulders and tie under the shirt's collar in front.


Step 3: Make a Red Sash

Create a sash using a length of inexpensive red material. A sash of about 6 inches wide works well. Make sure that there is enough length to go around the waist and still leave about 12 inches to drape down over one hip. Cut fringe at the ends of the sash. A long red scarf can also be used as a sash.


Step 4: Fit the Bandana

Take a piece of black material and drape it over your head. Determine the correct measurements needed to form a bandana. Cut out the mask from the same black material and tie it around your head again. Use a piece of chalk to mark where the holes should be cut for the eyes.



T-shirt fabric works well. However, be aware that it does stretch. Choose a fabric that has the least amount of give to it. Make sure the eye holes are not cut too big. Keep them only slightly larger than your eyes. Do cut the eye holes large enough to see through properly, especially if the costume is for a child who will be trick-or-treating.

Step 5: Add Gloves, Hat, Mask and Boots

Wear black gloves. A Zorro hat and mask can be found in most Halloween stores or online. However, the bandana also works without a hat. Wear black boots.


Step 6: Draw the Mustache

Draw a thin black mustache on your upper lip with a black eyeliner pencil. It is a good idea to look at photos of Zorro from the old series or from Antonio Banderas' film to get the shape just right.


Step 7: Add a Sword

Finally, don't forget to add a sword. Buy a play sword at a discount store or a Halloween store. Make sure it has a sheath. Take a piece of black material about 2 inches wide and long enough to tie around your hips. Loop the material around the sheath and tie it at an angle like a gun holster.