Jetpack costume sewing tutorial

When I first saw this pin on Pinterest, I knew I had to make one of these adorable jetpack costumes!

I wanted to sew one for my 4-year-old son. When I showed it to him, he begged me for weeks to do it. What I didn’t expect is that my older sons (ages 9 and 10) would also want one. And then all three of my daughters (ages 3, 6, and 7) wanted one! (The older boys have now decided that they want me to make them one that looks more like Jango Fett’s–so that will be coming sometime. . . . . .)

Here’s what I did to make the Jetpack costume! First, you’ll need red, silver, and gold Metallic Tissue Lame Fabric.
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You’ll also need some stuffing, such as Fairfield Poly-Fil Premium Polyester Fiber, White, Elastic- 1/2-Inch, cardstock, and Tacky Glue.

1. Cut 2 rectangles of the silver lame. 13″ x 14.5 ”

2. Cut 4 silver circles with 4.5″ diameter and 2 circles from cardstock or something a bit heavier with 4″ diameter. (I used a compass.)

3. Cut 10 gold strips (22 inches long) and 8 red strips (14.5 inches long), all about 2 inches wide.

4. Sew the 2 big rectangles with a 1/4 inch seam allowance along the longer edges.

5. Sew a circle to the top of each “fuel tube,” 1/2 inch seam allowance.

6. Before sewing the circles to the bottom, you’ll want to attach the “flame.” Sew the gold and red flames scattered across the middle, seam allowances both toward the center so they won’t show when the strips are hanging down.

7. Next, you’ll stuff the circle with the flame to the inside. Sew it about 2/3 of the way around, leaving open the area nearest the gold flames.

8. Turn right side out. Put the cardstock/cardboard circle in first to make the top of the fuel tank flat. Then stuff with your choice of stuffing.

9. Sew it closed by hand.

10. Put a good amount of Tacky Glue in the middle of the two fuel tanks. Find a way to “clamp” it together while it dries. (I pressed it in between some heavy blankets.) Let it dry completely.

11. Cut the elastic according to the size child who will be wearing the jetpack. I estimate 12″ for a 5-year-old, 16″ for a 9-year-old, and 18.5 ” for a 10-year-old. Hold it up to the child to determine the best place to sew the elastic and sew it on by hand.

12. The lame does fray a bit. I think it adds to make the flame more realistic. But if you want it to fray less, try a zig-zag stitch around them.