Homemade Kylo Ren Kids Costume

Since my son’s Star Wars birthday party, the boys in our house have been a “little” nuts about Star Wars. Combine that with all the buzz about the new Star War’s movie “The Force Awakens” and it is no wonder that B desperately wants to be Kylo Ren for Halloween. B even tried to talk me into letting him wear his Kylo Ren costume to his Cub Scout pack meeting this week. Which would have been awesome because they were having uniform inspection that week. I can just see him lined up with all the other Cub Scouts.

Before starting on B’s homemade Kylo Ren kids costume I did a lot of research. There isn’t a lot about Kylo Ren out there yet and mostly what I found were tutorials for elaborate cosplay costumes. But I wanted something fast, cheap, and easy. So I found some ways to get the overall effect without spending hours on my sewing machine or a ton of money.

For a quick overview, B and I did a video tutorial, but I list more details below in the blog post. The video isn’t great because I was trying to do everything one handed, but it doesn’t matter because B steals the show. He is so stinking cute.

Homemade Kylo Ren Kids Costume Tutorial

Kylo Ren Mask

I know that there are tutorials on how to make the Kylo Ren mask by hand, but you can get it cheap enough online that it was worth it to just buy it.

Kylo Ren Hood

I debated a long time on how to do the hood. I wanted it to be easy to make, but it also needed to be durable, easy to put on, and it needed to stay put. B is a crazy active boy and I knew he wouldn’t be fussy about how he was wearing the hood. That’s when I realized that Kylo Ren’s hood is basically a scoodie – a hooded scarf. Easy! And yes, the idea of Kylo Ren in a scoodie is hilarious.

So I cut out a scarf with ragged edges and a cape shape in the back like Kylo Ren’s. You don’t have to be too picky because it is supposed to look worn and ragged. kylo-ren-scoodie

For my son, here are the measurements of the cape. But it will need to be made bigger or smaller depending on the size of your child. When you first cut, I recommend making the scarf arms longer. You want it long enough to hang nicely over both shoulders and it is always easier to trim it then having to make it longer.


For the fabric I used a nice linen. I wanted something that would hang well and that also had a similar weave to Kylo Ren’s. Using nice fabric can make a world of difference in how something hangs. Burlap is cheaper and has a similar weave, but it is really itchy. B struggles enough with sock seams, I knew there was no way he was going to wear burlap. By using coupons, I was able to get the price down. You could also use flannel if you don’t like to mess with a hem. I don’t know if I would use knit though. It is too lightweight and looks too feminine for a Star Wars villain.

For the hood, I decided to double up the fabric to get a nice clean seam along the front and to make it hang nicely. To do the hood, just cut out a piece of fabric that is about 28 inches by 34 inches. Then fold it in half so that it is 34 by 14 inches. Along the fold, sew down the length about 1/4 inch from the edge. Then fold it in half again so that it is 14 x 17 inches. The part with the seam will be the front of the hood and the side with the fold will be the top. I then used a large bowl to trace a round edge along the top back of the hood and cut it out. To finish off the hood, I sewed along the back curve and down the back.


The next step is to sew the hood to the scarf. You just need to line up the middle of the scarf with the middle back of the hood and sew. To help the hood stay on, I also add a fastener at the front and two loops on the side. When you put the hood on, you thread the ends of the scarf through the loops and it helps them stay put and lets you play with the drape of the scarf a bit on the front.


After everything was sewn together, I went over the edges and unraveled the fabric to make it look like Kylo Ren’s. I also added some velcro to the top inside of the hood and the top of the helmet so that the hood would stay in place better.



Kylo Ren Ankle-Length Cloak

This was so easy to make. First I measured B’s shoulders and they were about 15 inches wide. If you are making a costume for somebody who isn’t as lean, you will want to take in to account the waist measurement too. Luckily B is a bean pole, so it made it easy. I decided that four strips of 8 inch fabric would do the trick to allow for some wiggle room and seams. I also used linen, but less expensive linen since how it hangs wouldn’t be as important and I wouldn’t be roughing up the edges. But I would still recommend using a heavy enough fabric that the ends of the cloak hang and swing around well.

To figure out how long to cut the strips, I measured from B’s shoulders to his ankles. You will then want to add a few inches to account for seams and the curve of the body. For B I cut 46 inch strips. Remember it is always easier to cut some length off then to add it later, so I always add a little more than I think I will need.

To figure out how far down you need to sew the strips of fabric together, you will want to measure from your child’s shoulders to just below where the belt will sit. For B’s costume I sewed down 19 inches. Just line up two pieces of fabric along the longest side and sew down about 19 inches. When you are done, you should have two pieces that are sewed together about halfway down.


I then lined up the two pieces along the shorter edge and sewed them together. This is the shoulder seam. You then fold it in half and sew down the side, leaving room for the arm hole. I started sewing about 9 inches down for my arm hole and then stopped 10 inches down from that. You will now have something that looks like the cloak, but without a neck hole. So I laid it out, grabbed a large bowl and traced a neck hole using chalk and then cut it out. Tada! Now you just have to try it on to make sure it fits and hem it.


I know there is another layer to the cloak, but for a child’s costume, I thought it was safe to skip it. Plus it is still warm here for Halloween and I didn’t want the costume to be too hot.


Kylo Ren Light Saber

I grabbed the Kylo Ren lightsaber for only $13 at Amazon.

Under Shirt and Pants

Kylo Ren’s pleated shirt is awesome, but there was no way I was doing pleats. Nope. And I hate sleeves too. A lot. So I bought a pair of black thermals because the ribbed texture was close enough and I figured B could use them as PJ’s in the winter. You can buy them on Amazon, but they are cheaper at Walmart. Because thermal pants have that opening on the front, I sewed it shut so that B wouldn’t have to worry about flashing anybody.

Gloves, Belt, and Boots

For the gloves, I bought some black work gloves at the Dollar Tree, but if you have some black snow gloves, those would work too.


I found the belt at a thrift store and just used a black sharpie to color in the gold buttons.


For costumes like this, I have also found that the boots have a huge impact. For B’s Obi-Wan costume last year I bought a pair of boots at a thrift store that his sister could grow into in a few years. That way I wasn’t wasting money on something that wouldn’t be used again. This year I have been to several thrift stores and haven’t found anything, so he is wearing an old pair of my cowboy boots. I can’t believe his feet are almost as big as mine! I am hoping we find something better before Halloween though.

We had so much fun taking photos. B didn’t want to take the costume off! Seeing how excited he was made all the work worth it. I love this little guy so much. He is all heart and always makes me smile.




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42 Responses

  1. Erica says:

    Amazing! I’m making one for my husband because the store bought ones are sold out everywhere. You are my life saver! I was stuck on how to do the hoodie, but yours is perfect! Thank you for the inspiration!

    • admin says:

      I was totally stuck for a long time on the hood too! But after seeing the store-bought ones in person, I am so glad I made it by hand. It looks so much better. The store-bought costume fabric is really flimsy. I’d love to see your photos of the finished product if you would like to share 🙂

  2. Michael says:

    Hello! Great work! I was wondering if you would take a commision to make the “scoodie.” what would it cost for just that with the velcro added inside the hood? Any interest?

    • admin says:

      Thank you so much for asking. But I don’t think I would be able to get it to you before Halloween. However, I do know a few excellent seamstresses whom I can ask.

  3. samantha says:

    This is awesome! I’ve been contemplating how to make this costume the for the last few weeks. I found some awesome fabric at Jo-Anns that mimics the armor for the arms, I’ll be making a shirt with it. Thanks again, this is great!

  4. Silke says:

    That looks awesome! Love your creativity and how you explain all steps in easy to follow bits. In all, would you say about two meters of linen fabric for a child’s outfit is sufficient? The thermo shirt also goes great with the outfit, I think as long as it looks rough and tough (villain style!), it’s a winner!

    • admin says:

      Thanks! I think I used almost 4 yards, but I also lined the hood so that you couldn’t see the seam on the inside. And you also want to make sure you get enough to make the scarf portion long enough. It adds up fast!

  5. Sarah M says:

    That is great! I am making one for myself and was struggling with the scarf/cloak/hood design until I found yours. Big question….how did you do the ragged edges on the scarf? Yours looks amazing and I’d like to try and replicate it!

    • admin says:

      Thanks! I roughed it up by pinching the edges between my index and thumb fingernails and running it along the edge. Since it was a linen, my fingernails were enough to loosen some of the threads. I hope that helps!

  6. kylo ren says:

    im in middle school and i love making costumes thank you for this website was stuck on the hood and you saved me from giving up.

  7. Theresa says:

    THANKYOU! I read this blog on a long road trip for xmas and have been itching to get making the costume for my 10 yr old son who is crazy about Kylo. His very tall for his age so shop costumes don’t fit. I finally got to make it yesterday and it looks great! He is wanting to wear it 24/7. We are having the same issue wiith the boots but I will find some somewhere.

    • admin says:

      So glad I could help! We finally found the perfect pair at a thrift store right before Halloween. They were a small pair of women’s boots. 🙂

  8. Jennie Jensen says:

    hi, I’m making the costume for my grandson, and your post has helped me most of the way, thank you for the help, especially the detail with velcro on the mask, is a great idea! Greetings from Denmark

  9. morri says:

    Hi this looks good. I want to do a costume for my daughters carnival at playschool. How tall is your kid? mine is 3 yo and about 1m.(39”) How much fabric would I need and how do you make a hood?(apart rom the scarf part xD.)

  10. Radana says:

    Thank you sooo much for this tuto! I’ve just finished the costume, it’s easy to do (even if I’m not really experienced in sewing), not expensive and what is the most important, my son is so happy about that!! He cannot wait to put it on for friday’s carnaval parade.
    This evening I’m the best mum in the world LOL
    greetings from Radana / France

  11. Renee Glismann says:

    hi just curious where did you buy the linen from an how much did it cost
    thank you

    • admin says:

      I got it at Joanns and hit the sales and used their coupons to bring the price down. The nice stuff I used for the hood is normally about $16 a yard, but there was a sale that brought it down to about $8. The cheaper stuff I used for the tunic was $9 a yard, but I used a 40% coupon.

      • Renee Glismann says:

        thank you just curious what color black for the hood as well for the tunic? i’m just curious since i found a sew classic hopsack linen fabric for 12 yard

        thank you

        • They were both black, but just a shade different since I bought cheaper linen for the tunic. I liked the subtle difference in color because it made it so that everything didn’t just blend together. But I don’t remember if I used the hopsack linen or not. I just rummaged around in the bolts and grabbed stuff that was on sale 🙂

          • Renee Glismann says:

            ok thank you very much i wounder if somehow my dad can help me ta get the linen as well as the mask an saber an maybe the boots as well i’ll just see what happens tomorrow when we go see Deadpool :3

  12. Renee Glismann says:

    i’m just thinking until i can somehow get the fabric of killin a black hoodie but don’t know what ta use for the long part

  13. Séverine says:

    Thank you for this tuto! There is another Kylo Ren in France, just looking like your son. The explanations were perfect!!! It was very easy to do even if I am not specially good at sewing! I’ve just finished the costume, after working only one evening on it. My son is so so so happy about his disguisement! And so am I!
    Thank you again!!!
    Séverine et Léo / Bergerac / France

  14. Nella says:

    I don’t understand the pattern of the scarf. I know you suggest 100″ in length but is it a random shape as shown in the photo? How long did you make it from neck edge to rectangular point downt the back? I am a “scientific” sewer and need details, details, details. Assignment from daughter in UK for 13 “scoodies” so must get on it

    • Sorry, I am a terribly non-scientific sewer, so patterns and I don’t always get along. But I have added a rough pattern with some measurements in the body of the post that should help. A lot depends in the size of the person though. This one was made for a 4-foot-tall child. Good luck making that many scoodies!

  15. Lorraine Larson says:

    My 8 year old son just researched this costume and found your blog!! How amazingly helpful!! Thanks for your tutorial, instructions, and example of patience and love as your cute son demonstrates his light saber. We are very grateful!

  16. Leah says:

    This is exactly what I was looking for to make my nephew a costume for his 10th birthday, thank you so much from New Zealand 🙂

  17. jory says:

    sorry if you already answered this, but did you hem the long strips all the way around?

  18. Elizabeth says:

    Thanks for this! I’m having trouble understanding the hood, but I hope to get it! My son is almost 9 and loved your video 🙂 He hopes to get something just like it. I hope I can figure out the hood and loops!! 😀

  19. Roxane says:

    Thank you SO much for this amazing tutorial! I made this costume for my 7 year old grandson and it turned out so great. I was looking for suggestions/pictures of the hood when I stumbled on your complete instructions. It saved me hours of trying to figure this out on my own. I bought a black linen-type heavier weave for the cloak (it was actually a curtain panel!) and a finer linen for the hood. We bought the mask and light saber. Thrift store boots, shirt and pants and the costume was complete.

  20. Ale says:

    Thank you very much. You are my hero!!!!!!

  21. KenzieKat24 says:

    Is there any chance your daughter would want a Rey costume? I saw this and thought…..oh…….I want to read an article about how to make a Rey costume so I can make one for myself.

    • Angie says:

      I wish! She is a funny little bug. She loves Princess Leia because she has awesome hair, shoots guns, and wears a long white dress, but is totally uninterested in anybody else in the franchise. This year, I think she may want to be Alice from Alice in Wonderland for Halloween!

  22. Amanda says:

    Monks cloth is a great fabric to use to get the weaved look from the movie although it’s not always user friendly (it frays a ton but glue helps) and needs to be dyed unless you can luck out and find it in black. JoAnn’s also carries a proper basketweave cosplay fabric that is a wonderful weight and already black however it’s also around $25 a yard so even with coupons it’s pricey. Monks cloth normally runs around $15 at JoAnn (before coupons) and $8 at Walmart per yard.

    I have a crazy child who is willing to do whatever as long as the costume is screen accurate so he got the pleated sleeves and tunic plus the surcoat and hood/scarf and I was struggling with the scarf part so this helped out a ton.

  23. Angie Holder says:

    How much fabric total did you buy for this costume?

    • Angie says:

      I think I used almost 4 yards. But how much you need depends on how large you make it. The measurements for this pattern were designed for a 4-foot child who is pretty skinny. But the pattern is designed to be adapted according to size. I would recommend figuring out how big your panels will need to be to fit, and then take that to the fabric store and they are great about giving you an idea on how much you need.

  24. Klara Fansler says:

    Do you have any tips for sizing the hood up? I’ve never had to resize a pattern before and I’m totally lost on what I should even do. I don’t have a lot of experience but I really would like to make this pattern because you did such a good job on it.

    • Angie says:

      Thanks! The hood on this pattern is already really oversized, so you would might be fine with this size unless you were making it for a pretty large grownup. I would recommend finding a hoodie that is oversized on you. I would then measure the depth and height of the hood, adding a couple of inches to both, and then use that size. So if the hood is let’s say 16 x 19, I would add a couple of inches and plan on 18 x 21. Then I would cut out a piece of fabric that was 36 by 42. Then fold it in half so that it is 18 by 42, etc. The great news about hoods is that it isn’t hard to take some off if it is too big. I hope that helps, let me know if you have questions.

  25. Britt says:

    Hi, would you be able to create the costume for me and J will pay you? j need it for my son who is 6 for his birthday ah the end of the month!

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