DIY BB-8 Droid Hat & Shirt Costume

We may earn money or products from the companies mentioned in this post. Please see policies for more information.

We had the opportunity for a fun quick run through EPCOT thanks to DisneySMMC and GoGo Squeez! Some local blogger friends and I decided to make fun running costumes all themed around Star Wars. The boys helped me decide on a costume and this year we went with BB-8! BB-8 is a new droid from Star Wars: The Force Awakens and even though we know nothing about him, I’m betting he’ll be our new favorite.

DIY BB-8 Droid Costume - hat and shirt!

This post contains affiliate links.

I knew while making this that others would likely want to make this costume as well. Even if it’s just the hat. My youngest wore the hat when we visited Hollywood Studios just before Star Wars Weekends and got TONS of comments!

DIY BB-8 hat

I put together a video of how I made mine using freezer paper (I actually cut mine out with a Silhouette but the video is for those that don’t have one). You could also use the colored templates listed below and just print on t-shirt transfer paper for an even easier project.

BB-8 t-shirt costume

For the shirt you’ll need:

DIY BB-8 Costume Hat

For the hat you’ll need:

  • white hat
  • pipe cleaners (white and black or grey)
  • orange felt
  • black felt
  • grey felt
  • sharp scissors
  • low-temp hot glue gun
  • black Sharpie

Here’s the video showing you how to make it but basically for the shirt you’re cutting the template out of freezer paper, iron onto the shirt waxy side down with the steam setting off, paint over the stencil using a spouncer for best results. For the hat you’re just cutting shapes out of felt and hot glueing them onto the hat. It really is easy!

DIY BB-8 Droid hat & shirt costume. Perfect for a Star Wars Run Disney costume, halloween or just a trip to Disneyland or Walt Disney World!Here are the templates for your personal use:

T-shirt Color

T-shirt cut-out templates

Hat circle templates – you’ll have to cut some shapes out on your own and find something to trace for the drawn on shapes, but those should be pretty simple. I found that using the templates for the circles made a MUCH more even circle than I could have ever cut out! Use the photo of the hat or a photo of BB-8 as your guide!

Here were the other costumes that morning:

Star Wars Run Disney costume ideasHan / Chewie / Storm Trooper / Darth / R2D2

Last year I went as Olaf and it was so fun to see all your costumes so please send me photos if you make your own version of BB-8!


(Visited 393 times, 4 visits today)

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!


  1. I love the hat! Do you have a pic of the back? I am curious how you attached the pipe cleaners. Thanks!

    • Here’s a quick snap.

      The white one is wrapped around the top “button” and the black one around a seam, both secured with hot glue.

  2. Thank you for this tutorial. I can’t find a bb8 shirt so this will help me make one! (Hopefully being that I’m creatively challenged.)

  3. Ali Bender Reply

    Thank you so much for all of the detailed information! I used it to make my own costume for this Halloween and was so grateful to have all the specs right here! 🙂

  4. What a great costume! How did you design your templates? I am working on a bb8 cosplay for my daughter and yours is by far the best. For the dress, I am making I think it will need more than four of the circular designs. Any insight into your process would be awesome.

Write A Comment