Last Halloween, my little boy was all about Thomas the Tank Engine (age 2.5). I didn't really care for the commercial Thomas costumes you can buy in the store, so I set out to make one. It was so simple and cheap to make.
Here's what you need:
-gray material (I chose a soft jersey material)
-iron-on transfer paper
-needle & thread
Here's what I did:
-found a photo of Thomas' face and enlarged it to 8.5x11 size. I printed it onto an iron-on transfer.
-cut out the face closely to the edge
-ironed on Thomas' face onto gray material (cut out in a large circle)
-cut out two small circles from the black felt
-attached Thomas' face (gray circle with face) onto the sweatshirt by hand stitching all around the circle
-attached the felt circles (buffers) to the knees of the sweatpants by hand stitching
I added a train conductor hat and voila...I was done & he looked adorable on Halloween!