DIY Baymax Costume (from Big Hero 6)

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80+ blog buddies and I got together to bring you 80+ DIY Halloween costumes, including this DIY Baymax Costume (2 different ways)! I’m teaming up with Jamie Dorobek and her handmade Halloween costume site, Really Awesome Costumes to bring  you all kinds of easy  DIY Halloween costume ideas.

DIY Baymax costume (2 ways!)Along with our Baymax costume I’m sharing 88+ more really awesome handmade costume ideas from talented bloggers everywhere!

We often make fun costumes using solid tshirts, shorts/pants, paper and duct tape. I love combining these materials to get lots of different looks!

For suited up Baymax you’ll need a red shirt, pants/shorts, purple duct tape, red paper, white paper, elastic string and a black marker. For the shirt “plate” I covered a self healing mat with duct tape (I LOVE using these mats to cut duct tape because you can stick it on and it comes right back off).

DIY Baymax costume (2 ways!)Using a ruler and craft knife,  trim to shape.

DIY Baymax costume (2 ways!)Peel off and stick to the shirt

DIY Baymax costume (2 ways!)For the mask you could go quite a few directions. We decided to use a paper mask and used this template from Happy Thought.

DIY Baymax costume (2 ways!)Use this template to cut a mask out of red paper. I made mine a bit larger than the template I printed. Fold and secure with glue.

DIY Baymax costume (2 ways!)Next, sketch and cut out the “horns”

DIY Baymax costume (2 ways!)I decided to attach these with staples but will cover the staples with duct tape circles to protect their heads.

DIY Baymax costume (2 ways!)Using whatever you have lying around, cut 2 circles out of duct tape using the self healing mat technique.

DIY Baymax costume (2 ways!)

DIY Baymax costume (2 ways!)

DIY Baymax costume (2 ways!)Next we’re making the eye cutout, just trace the shape on a piece of white cardstock and cut out.

DIY Baymax costume (2 ways!)

DIY Baymax costume (2 ways!)Trace small circles for the black eyes with a line in between.

I always try to use a person to figure out where eye holes go by having them put the mask on and drawing a small hole where their eyes are. Cut out the eyes in the red part of the mask a bit bigger than the eye holes in the white part.

DIY Baymax costume (2 ways!)

And the mask is done!

DIY Baymax costume (2 ways!)I punched small holes behind the ears and reinforced with a bit of duct tape for the elastic string.

DIY Baymax costume (2 ways!)

DIY Baymax costume (2 ways!)

DIY Baymax costume (2 ways!)For the white Baymax just repeat the steps for the mask using white cardstock and draw the eyes right on. You could stuff a shirt with a pillow for some extra padding 😉

DIY Baymax costume (2 ways!)

DIY Baymax costume (2 ways!)Hairy Baby! (have you seen the Big Hero 6 trailer?)

DIY Baymax costume (2 ways!)

And now it’s time for tons more DIY Halloween costume inspiration! Join in on the BLOG HOP! Click on the links below each collage to get the detailed instructions about how to make the costume pictured, just like mine above. Don’t forget to follow the Handamde Halloween Costumes Pinterest Board for even more DIY costume greatness!
101+ Handmade Halloween costumes at Creating Really Awesome Free Things


88+ Handmade Halloween costumes at Creating Really Awesome Free Things

1. Handmade Baby Hamburger Costume

2. DIY Baby Game Boy Costume

3. DIY Minecraft Steve Costume

4. Football Brothers Halloween Costumes with DIY Pads and Onesie

5. Star Trek Halloween Costume for Kids

6. A Bee and Her Keeper

7. No Sew Magician Costume

8. Flint Lockwood Costume

9. Pinocchio

10. Marty McFly

11. Princess Wedding Dress Costume

12. Handmade Lalaloopsy Doll Costume

13. Homemade Toothless Costume

14. DIY Mermaid For Less Than $20 (No-Sew Option)

15. Easy Tinker Bell Costume

16. Mario and Luigi Go Kart Costumes

17. Dog The Bounty Hunter and Beth

18. Family Monsters University Costumes

19. Scooby Doo family costumes

20. DIY Storm Cloud Costume


88+ Handmade Halloween costumes at Creating Really Awesome Free Things

21. Cheap and Easy DIY Spider Costume

22. Easy Tin Man Costume

23. No Sew Bee Costume

24. Planet Halloween Costumes

25. DIY Cheshire Cat Costume

26. DIY Instagram Board

27. Elsa crown

28. Dog Collar Ruffles

29. DIY Pineapple Baby Costume

30. DIY Lego Movie Costume

31. Weeping Angel Costume

32. Disney Planes Costume: Dipper

33. Easy Pirate Costume

34. Easy Costume Idea – Renaissance Girl

35. 10 Minute Homemade Jellyfish Costume

36. DIY Cat Costume

37. Lucy And Ricky Costumes

38. Easy Frozen Costumes

39. Easy Greek Goddess Costume

40. DIY Family Willy Wonka Costumes

101+ Handmade Halloween costumes at Creating Really Awesome Free Things

41. DIY No Sew Maleficent Costume

42. No Sew Pineapple Halloween Costume

43. Graveyard Bean Bag Toss: Trunk or Treat Car Costume

44. DIY Teenage Mutant Ninja Turtles Costumes

45. DIY Raccoon Costume with Printable Mask

46. Easy WildStyle Lego Movie Costume

47. Simple Hello Kitty Costume

48. No Sew Minnie Mouse Costume

49. DIY Inspector Gadget and Penny Costumes

50. DIY Frozen Elsa Dress Baby Edition

51. Fairy Princess Dog Costume

52. DIY Hashtag Halloween Costume

53. Toddler or Baby Egg Costume

54. Easy No Sew Olaf Costume

55. DIY Baymax Costume

56. DIY Tooth Fairy Costume

57. Baby Short Stack Pancake Costume

58. Elephant and Piggie Halloween Costumes

59. Instagram Halloween Costume

60. Peter Pan & Mr. Smee Halloween Costume

88+ Handmade Halloween costumes at ReallyAwesomeCostumes.com

61. Wildstyle Costume from the Lego Movie

62. Fred and Wilma Couples Costume

63. Viking Family Costumes

64. DIY Cruella de Vil Costume for a child

65. Disney Frozen Olaf Halloween Treat Bucket

66. How to Make a Minecraft Steve Head

67. DIY Harry Potter Costume

68. DIY Duck Dynasty Costumes

69. No Sew Cupcake Baker Halloween Costume

70. DIY Skunk Mask

71. Ghostbusters Proton Pack DIY

72. Frozen Anna Costume Tutorial

73. Candy Corn Costume

74. Paw Patrol Halloween Costume

75. No Sew Toothless Dragon Costume

76. DIY Robot Costume

77. Wonder Woman Costume

78. Reese’s Peanut Butter Cup Costume

79. Thrifted Gentleman Spy DIY Halloween Costume

80. DIY Boy Garden Gnome Costume

81. Group Costume: Bob Ross, Happy Tree, & Squirrel

82. DIY Blues Brothers Costumes

83. Snow White Costume

84. Peacock Princess Costume

85. Scarecrow Costume

86. Easy Teenage Mutant Ninja Turtle Costume

87. Handmade Teddy Bear Costume

88. Princess Elsa and the Spy Kid

89. DIY Baby Koala costume

What handmade costume ideas did you love the most?! Be sure to click over to get the costume instructions, pin the costume, and let them know you love it! Also, follow the Handmade Halloween Costume board on Pinterest!

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Allison Waken is a wife, mom of boys and Phoenix, AZ native. She has been creating inspiring content for All for the Boys since 2011. Allison loves travel, movies and spending as much time as possible with her family while she can!

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