![Child in fighter pilot costume Child in fighter pilot costume](https://contentgrid.homedepot-static.com/hdus/en_US/DTCCOMNEW/Articles/AmyBaesler-HerToolBelt-FY22-FighterPilotBoxCostume-Header.jpg)
![Amy Baesler contributorImage](https://contentgrid.homedepot-static.com/hdus/en_US/DTCCOMNEW/Articles/AmyBaeslerHeadshot.jpg)
A Note From The Home Depot
Creating an out-of-this-galaxy DIY just got easier. In this blog post, Amy Baesler shares step-by-step instructions so you can recreate this fighter pilot box costume. To explore official Star Wars products available at The Home Depot, click here.
Fighter Pilot Box Costume
![Child in fighter pilot costume Child in fighter pilot costume](https://contentgrid.homedepot-static.com/hdus/en_US/DTCCOMNEW/Articles/AmyBaesler-HerToolBelt-FY22-FighterPilotBoxCostume-Photo19.jpg)
Create your own fun space-themed costume simply out of moving boxes. This rocket is a fun project for your space and science fiction enthusiasts.
Grab Your Tools and Materials
![Ryobi hot glue stick next to bottles of spray paint Ryobi hot glue stick next to bottles of spray paint](https://contentgrid.homedepot-static.com/hdus/en_US/DTCCOMNEW/Articles/AmyBaesler-HerToolBelt-FY22-FighterPilotBoxCostume-Photo16.jpg)
Tools:
- Razor Blades
- Hot Glue Gun
- Ruler
- Straight Edge
Materials:
- 1 Medium Shipping Box
- 1 Small Shipping Box
- 1 Large Shipping Box
- 1 Self Stick Single Face Roll
- Hot Glue Sticks
- Painters Tape
- Rope/Straps
- Spray Paint Primer
- Behr White Spray Paint
- Behr Black Spray Paint
- Behr Gray Spray Paint (Lunar Surface)
- Behr Red Spray Paint (Flirt Alert)
Step 1: Main Box
![illustration of cuts on a box illustration of cuts on a box](https://contentgrid.homedepot-static.com/hdus/en_US/DTCCOMNEW/Articles/AmyBaesler-HerToolBelt-FY22-FighterPilotBoxCostume-Photo1.jpg)
![illustration of a box folding illustration of a box folding](https://contentgrid.homedepot-static.com/hdus/en_US/DTCCOMNEW/Articles/AmyBaesler-HerToolBelt-FY22-FighterPilotBoxCostume-Photo3.jpg)
Assemble a medium cardboard box (approximately 15 ¼” x 21” x 16 ½”). Cut top and bottom of box leaving 9” x 15 ¼” in the back. Cut down 6” from box top at 9” from back and 11” from back.
![Hot gluing a box together Hot gluing a box together](https://contentgrid.homedepot-static.com/hdus/en_US/DTCCOMNEW/Articles/AmyBaesler-HerToolBelt-FY22-FighterPilotBoxCostume-Photo2.jpg)
Measure over 2” from the front side flap, measure down 6” on the front corner, and cut between the 2” mark and 6” corner mark. Measure over 3” from each front flap top corner, measure down 6” on the front corner, and cut between the 3” mark and 6” corner mark. Glue the front and side flap diagonal cuts together.
Step 2: Create the Nose
![illustration of box dimensions illustration of box dimensions](https://contentgrid.homedepot-static.com/hdus/en_US/DTCCOMNEW/Articles/AmyBaesler-HerToolBelt-FY22-FighterPilotBoxCostume-Photo6.jpg)
Cut 2 pieces that are 15 ¼” x 21 ½”, mark up 5 ½” from bottom (the 5 ½” can be a flap). On the top, find center and mark 8” a cross. Cut diagonal from 8” top marks down to 5 ½” side marks.
Cut 2 pieces that are 10 ½” x 21 ½”, mark up 5 ½” from bottom (the 5 ½” can be a flap). On the top, find center and mark 5” a cross. Cut diagonal from 5” top marks down to 5 ½” side marks.
![illustration of folding box illustration of folding box](https://contentgrid.homedepot-static.com/hdus/en_US/DTCCOMNEW/Articles/AmyBaesler-HerToolBelt-FY22-FighterPilotBoxCostume-Photo4.jpg)
Glue 15 ¼” flaps to front of main box. Glue 10 ½” flaps onto 15 ¼” flaps.
![gluing together stacked boxes gluing together stacked boxes](https://contentgrid.homedepot-static.com/hdus/en_US/DTCCOMNEW/Articles/AmyBaesler-HerToolBelt-FY22-FighterPilotBoxCostume-Photo5.jpg)
Then glue the diagonals together.
Step 3: Thrusters
![illustration of a cylinder dimensions illustration of a cylinder dimensions](https://contentgrid.homedepot-static.com/hdus/en_US/DTCCOMNEW/Articles/AmyBaesler-HerToolBelt-FY22-FighterPilotBoxCostume-Photo7.jpg)
Cut 4 pieces of single face roll 9” x 26 ¼”. Roll up and glue each piece in a cylinder shape that is about 4 ¼” diameter.
Step 4: Make the Wings
![3 illustrations of box dimensions 3 illustrations of box dimensions](https://contentgrid.homedepot-static.com/hdus/en_US/DTCCOMNEW/Articles/AmyBaesler-HerToolBelt-FY22-FighterPilotBoxCostume-Photo9.jpg)
![hot gluing box cut outs together hot gluing box cut outs together](https://contentgrid.homedepot-static.com/hdus/en_US/DTCCOMNEW/Articles/AmyBaesler-HerToolBelt-FY22-FighterPilotBoxCostume-Photo8.jpg)
Cut 8 wing pieces that are 9” at the bottom and 5” centered at top and 16” tall. On 4 of the wing pieces, cut ½” off the bottom.
Cut 4 pieces that are 1” x 42” (can be multiple pieces). Separate 16” wing and 15 ½” wing about 1” apart, then glue and wrap the 1” strip around the sides and 5” ends of the wings. Trim the strip ends to match the wing end angle.
Step 5: Attach Wings and Thrusters
![illustration of the back of the pilot box costume illustration of the back of the pilot box costume](https://contentgrid.homedepot-static.com/hdus/en_US/DTCCOMNEW/Articles/AmyBaesler-HerToolBelt-FY22-FighterPilotBoxCostume-Photo10.jpg)
On the back of the main box mark down 1” and 5 ½” from the top. Mark up 2 1/8” and 6 ½” from the bottom of the top. Glue center of thrusters at the 1” and 2 1/8” marks. Glue wings to the box at the 5 ½” marks and 6 ½” marks.
Step 6: Nose Cone
![illustration of the front of a partially finished fighter pilot costume illustration of the front of a partially finished fighter pilot costume](https://contentgrid.homedepot-static.com/hdus/en_US/DTCCOMNEW/Articles/AmyBaesler-HerToolBelt-FY22-FighterPilotBoxCostume-Photo12.jpg)
![the fighter pilot costume complete, but unpainted the fighter pilot costume complete, but unpainted](https://contentgrid.homedepot-static.com/hdus/en_US/DTCCOMNEW/Articles/AmyBaesler-HerToolBelt-FY22-FighterPilotBoxCostume-Photo11.jpg)
Cut the nose cone to fit on the end of the nose and glue in place.
![Taping the open gaps of the boxes together Taping the open gaps of the boxes together](https://contentgrid.homedepot-static.com/hdus/en_US/DTCCOMNEW/Articles/AmyBaesler-HerToolBelt-FY22-FighterPilotBoxCostume-Photo14.jpg)
I used painter’s tape to cover the cardboard edges and seams.
![fighter pilot box costume partially painted fighter pilot box costume partially painted](https://contentgrid.homedepot-static.com/hdus/en_US/DTCCOMNEW/Articles/AmyBaesler-HerToolBelt-FY22-FighterPilotBoxCostume-Photo13.jpg)
Then I used spray paint primer to paint the costume.
![finished fighter pilot box costume finished fighter pilot box costume](https://contentgrid.homedepot-static.com/hdus/en_US/DTCCOMNEW/Articles/AmyBaesler-HerToolBelt-FY22-FighterPilotBoxCostume-Photo15.jpg)
The body of the fighter ship is painted white. The windshield is painted black and the inside of the thrusters. A 3” wide strip is painted red along the nose and some accents on the top wings. The thrusters are painted gray and random gray distress paint splotches around the body.
![kid in fighter pilot box costume kid in fighter pilot box costume](https://contentgrid.homedepot-static.com/hdus/en_US/DTCCOMNEW/Articles/AmyBaesler-HerToolBelt-FY22-FighterPilotBoxCostume-Photo18.jpg)
Finally hot glue or tie straps or rope to the underside of the top of the wings to fit the ‘pilot’ wearing the fighter.