Well, I thought for sure that the Redhead would want to be Emmett for Halloween. He actually had a hard time deciding, but when we found out that our neighborhood carnival was going to be early (Oct. 1st!) he quickly decided on Benny from the Lego Movie. Totally doable.
This annual carnival is my boys' FAVORITE Halloween activity. Without a class party or anything, this is their chance to show off their costumes to their friends. Better than trick-or-treating. So I just HAD to get their costumes done (super) early. It was worth it, they were super excited.
This is the first costume I've paper mached for! I started with a balloon, a costco frozen pizza box, and washi tape.

I think this is after 2 coats. The boys helped me. I did four coats total (drying all day or overnight between each one).

I made it longer than needed so we could cut it to the right shape when it was all dry. I let my detail-oriented husband cut the whole and cover it with duct tape. We covered the pizza box on the inside, too.

Of course we 'broke' the helmet - just like Benny's!

For the tanks he wears on his back I just bought a cheapo pack of paper towels ($1.50/3) and covered two of them in blue duct tape. We added a cardboard piece to the top.

We couldn't figure out how to attach them to the shirt... Finally I safety pinned and duct taped some elastic to the back (pinned through the tape and some paper towel) and the Redhead helped me cover the elastic with blue sharpie. That part was pretty weak looking, but did the trick.

We used EXACTLY one roll of duct tape. And the paper towels aren't totally covered, there is some white showing on the back where no one will see.

For the shirt - freezer paper stencil, of course! I really wanted a basic royal blue sweat suit for this, but couldn't find one! Maybe it's too early... I settled on a thermal shirt + athletic pants. Not as 'space suit-y' but it did the trick.
The great thing about freezer paper stencilling is you can cut out the whole thing and do multiple colors at once. But this one I found easier to think of like screenprinting, and I did 3 'passes', one for each color.
You can see the process here:

My 'registration' on the last stencil was a little off, but I'm okay with it! Benny is a 1980-something spaceguy, and his logo is partially scratched off. I'm pretty happy with my interpretation. (This really didn't take that long, I swear!)
Come the day of the carnival, the Redhead is OVERJOYED to have all of his costume pieces completed! He laid out everything and rearranged them multiple times so it was ready to go.

Finally. 5:55pm - time to go.

Done and done!

(Not my son's actual face - but the smile is about the right size ;)
One happy 1980-something spaceman!
SPACESHIP!