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Making Elliot a Big Hero 6 costume has been on my to-do list ever since I made Quinn a DIY Baymax costume last year. Hiro is Baymax’s little buddy just like Elliot is Quinn’s little buddy, it’s the perfect costume pair for my two guys!
I kept this costume completely no-sew by utilizing a purple hoodie sweatshirt, felt or fleece, a pair of gloves and fabric adhesive.
Sometimes making a costume can be a little overwhelming so I always start with the easiest part. I cut out red circles of felt and attached it to the chest of the sweatshirt using fabric fusion. When tracing on felt, I like to use a sharpie of the same color. You can turn the felt over and the marker outline doesn’t show through!
The center red oval was a little trickier because I used a zipper sweatshirt. I cut it in half and carefully glued it along the edge of the zipper so it fit back together perfectly.
For Hiro’s helmet stripes, I had Elliot try the hoodie on and used duct tape to mark where I wanted them to be on the hood. I used a ball inside the hood to hold its shape while I glued on the red stripes.
The trickiest part for me was the ears on the helmet. I started by cutting out purple circles and then sketching the rest of the ear on cardboard for a template. Then I cut out purple and red felt to create the ear tip. I ended up sticking a piece of thin plastic between two felt “ears” to make sure it stood up on the helmet. Hiro doesn’t have floppy ears on his helmet!
The fabric fusion won’t work with the plastic so I used a hot glue gun to attach the felt pieces to either side of the plastic ear shape.
To create the illusion of a black under shirt, I glued two full sheets of felt to the bottom of the sweatshirt. I also added a strip of purple felt above the knuckles of black knit gloves to complete the look. Elliot wore black pants but if you wanted a full costume effect you could add felt to the pants as well!
I think our Hiro costume turned out pretty cute. What do you think?
By the way you can pick up materials to make your own Big Hero 6 costume at Walmart, along with cool Big Hero 6 merchandise and the Big Hero 6 Blu-Ray/DVD + Gift With Purchase Set (available in store 2/24/15).
- Your purchase of the Big Hero 6 Blu-Ray/DVD + Gift With Purchase Set includes a digital movie on Vudu while supplies last! Simply scan your receipt using the Savings Catcher in the Walmart app. Then look for a message on your phone or email. Now you can watch Big Hero 6 on any device!
We are ready for some sweet Big Hero 6 movie recreation with our costumes!
Who’s your favorite character from Big Hero 6?
Don’t miss my other Big Hero 6 posts:
Jenna Wood says
This is just too cute- and I could easily see how I could create the other character’s looks from your techniques! I just might have to be Honey Lemon for Halloween! #client
Leah says
I love this! My 3 year old wants to be Hero for Halloween and wants his daddy to be Baymax. With the cold weather we had last year the sweatshirt would be perfect. Where did you find the plain purple sweatshirt?
Karen says
Definitely try local stores like Walmart or Target. And check the girls section too, they are more likely to carry a purple sweatshirt. However Amazon has lots of options too, here is one I found: http://amzn.to/1NtOA1W.