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DIY Thomas the Train Costume

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Little girl with braids wearing engineer costume and Thomas the Train box costume

This DIY Thomas the Train Costume you can make from a cardboard box is so adorable, your little train engineer will be thrilled!

Smiling little boy wearing a train engineer costume and wearing the cardboard Thomas the Train costume!

When I asked O what he wanted to be for Halloween this year, and once I explained the concept (I don’t think he remembers last year), the answer was a resounding “TRAIN!” And if you have or have had a preschooler, I’m sure you know that it was not just any train, it HAD to be similar to a THOMAS the Train costume (otherwise known as Thomas the Tank Engine if you really want to be accurate).

The kid looooves Thomas. I tried convincing him maybe we should think outside the box and go for Thomas’ trusty friend Percy maybe? Or Toby? But no, Thomas the Train is the fave. So a look alike DIY Thomas the Train costume it is!

Finished cardboard box Thomas the train costume on the floor!
Finished cardboard box Thomas the train costume on the floor!

(PSST! Get the Train Engineer Costume with overalls, hat and kerchief HERE!)

I knew I wanted the DIY Thomas the Train costume to be 3D and I had some boxes sitting around so I figured that was the perfect place to start. I grabbed a few other things from Michaels, got a toy Thomas from the play basket for reference and got to work.

I feel like I should say that of course, making vehicle costumes out of boxes is not my original idea. They’re all over the internet. Pinterest even has quite a few Thomas the Train costumes. But I wanted to share my method since I didn’t reference any other tutorials and just figured it out as I went along.

DIY Thomas the Train Costume Supply List

DIY Thomas the Train Costume Instructions

Two cardboard boxes, a round cardboard box with lid and flat wooden circles in large and small sizes on a counter

I didn’t end up using those big wooden circles pictured above, instead a I used a couple 4 inch paper mache lidded boxes like the one in the middle.

My first step was a sketch to figure out the basic volume of my Thomas the Train inspired costume.

Pencil drawing of what the Thomas the Train box costume will look like

I pretty much approached this like building an architectural model, I drew it first and then tried to build it with the minimum possible number of seams and pieces.

I cut out the bottom of the box and then measured and drew my cuts on the top flaps. I know it doesn’t make a lot of sense in this picture.

Top flaps of a cardboard box with pencil lines drawn on it
The top flaps of a cardboard box cut to make the shape of Thomas the Train

But once you cut out the middle and fold up the side flaps…

The top flaps of a cardboard box cut to make the shape of Thomas the Train

It kinda starts to look like a train, right? Next I added Thomas’ roof.

The top flaps of a cardboard box cut to make the shape of Thomas the Train with a toddler smiling in the background

Cheesy “helper” recommended but not required…

The top flaps of a cardboard box cut to make the shape of Thomas the Train, this time with a roof added to the back
Unpainted Cardboard box in the shape of Thomas the Train, the body is complete

After the roof, I added the piece across the front and started painting it.

Cardboard box train shape painted blue with a black roof

Then I took that other boot box from the first picture and made the red platform that Thomas’ body sits on.

Cardboard box train shape with this red base box added to the bottom

One thing I have learned over the years of painting furniture is that red paint is really frustrating. It takes many many coats to get even opaque coverage. A lot of Thomas’ markings are red lines and I could just see myself painting them over and over and over and still having blue show through.

So I drew his markings in Illustrator and printed them out on cardstock instead. And then I carefully cut them out and glued them to his sides like decals. It worked out great and the lines are straight and even, much neater than I could have ever painted them!

Piece of paper with decorative red rectangle and half circle and yellow number 1 to cut out and paste to the side of the train

Then it was time to figure out Thomas’ face. When I googled Thomas the Train Costumes, I mostly saw flat faces. And they were plenty cute and that was what I was planning to do because it’s easy. But then about halfway through I had the crazy thought to try making a 3D face.

I mean, the 3D face is kind of what Thomas and his friends are known for, right? So I ran my 3D face scheme past my husband. And he said, “I don’t know…that sounds kind of ambitious.” Which to my ears, actually sounded like a challenge.  A

nd I can’t back down from a craft challenge. Plus I figured, if it didn’t work out, I could always go back to plan A!

Round paper mache cardboard box with lid on a counter

So I started with one of these lidded paper mache boxes from the craft store. 

I measured, marked and cut it to fit onto the front of Thomas’ body.

The base of a round cardboard box with about one third cut away
The round cardboard box with two thirds cut away to make the shape of the train's face
Round cardboard base attached to the front of the train shape

This last picture shows the lid of the box back on and that was going to be the base for Thomas’ face. After thinking for a bit, I decided paper mache sounded like my best bet.

Lid of the round cardboard box with crumpled newspaper covered in blue painters tape to make the 3d shape of Thomas the train's face

First I sketched Thomas’ face on the box lid, then I used crumpled and rolled paper covered in masking tape to sculpt his face. For most of these steps, he looks suuuuper creepy. Sorry! But, it’s Halloween so it’s cool, right? At this point I was going off my memory of the last time I did paper mache which might possibly have been making pinatas in middle school spanish class. I mixed half white glue with half water, tore up some strips of the Onion and got to work.

Lid of the round cardboard box with paper mache over it to make the 3d shape of Thomas the train's face

Once that dried, I tried painting it but it was way too bumpy and lumpy for my perfectionist tendencies. So that’s when I had my next crazy idea. I said to my husband, “What if I spackle him?” To which he replied, “I don’t know…” in a very skeptical tone of voice.

If you haven’t noticed, when Aa thinks something sounds like it might be a crazy idea, I, of course, decide that it’s brilliant and it will work! We spackled all kinds of things in architecture school, I figured why not try it?

Paper mache train face with rough spackle on top

Unfortunately, I only had half a little container of spackle that was about 80% dried out. Undeterred, I added some water and stirred. And stirred. And stirred. And hey! Guess what! You can reconstitute spackle! So Thomas got spackled…

Then I sanded and re-spackled and smoothed until he looked waaaaay better.

Paper mache train face with smoothed spackle on top

After some paint, it turned out I was right, the 3D face was awesome! And Aa was sufficiently amazed.

The next thing I tackled was his wheels. I used two of those round paper mache boxes in a smaller size and made six wheels from the tops and bottoms.

I painted them blue and then decided they needed a little detail. Having just had so much success with the decals I used to put the lines on Thomas’ body, I drew out a sunburst shape on some thick magazine paper and cut them out.

A black magazine page with train spoke shapes cut out of it and a craft knife sitting next to it

Then I painted them black and glued them to the wheels!

Blue half wheels with black spokes for the train
Smiling Little girl with braids wearing engineer costume and Thomas the Train box costume
Side view of Little girl with braids wearing engineer costume and Thomas the Train box costume

After that I attached the wheels, made a funnel out of a toilet paper tube, added the bumpers and fashioned some straps from the handles of a reusable shopping bag (does everyone else have approximately 7,000 of those?!)  And O’s DIY Thomas the Train costume was ready!

Finished cardboard box Thomas the train costume on the floor!
View of the back of the cardboard box train costume
Closeup of the cardboard train's cute face

Of course O is dressed as the train engineer who drives Thomas! He wore this once already and it was a huuuuge hit!

(And no I didn’t make the Engineer costume, I got it on Amazon. I’m not totally insane.  😉 And because I get asked, at 3 yrs old, O, who was pretty tall, fit comfortably into the 3T-4T size.

Smiling little boy wearing a train engineer costume and wearing the cardboard Thomas the Train costume!
Little girl with braids wearing engineer costume and Thomas the Train box costume
View of the back of the cardboard box train costume
Smiling front view of Little girl with braids wearing engineer costume and Thomas the Train box costume
-Little girl with braids wearing engineer costume and Thomas the Train box costume looking over her shoulder

Choo! Choo!

Tips and Tricks for making your own DIY Thomas the Train Costume…

  • Don’t worry about the exact dimension of the boxes I used, find one that fits your child and go from there.
  • Many people have recreated this Thomas the Train costume without the 3D face. I promise, it still turns out extremely cute, just find a picture of Thomas’ face and print it out at the right size!
  • If the weather forecast is questionable, you might want to give you Thomas the train costume a little spray with some poly or other clear protectant. Or have your little one wear a clear poncho on top!
  • One more time, HERE is the link for the train engineer costume. If you’re really daring, grab a train whistle for your little one too! Choo Choo!
Yield: 1 train cosutme

DIY Thomas the Train Costume

Smiling little boy wearing a train engineer costume and wearing the cardboard Thomas the Train costume!

Make an adorable Thomas the Train inspired Halloween costume from an old cardboard box!

Prep Time 10 minutes
Active Time 2 hours
Total Time 2 hours 10 minutes
Difficulty Intermediate
Estimated Cost $10

Materials

Tools

Instructions

  1. Cut the cardboard box flaps and fold up to make the train shape, cut out the bottom of the box.The top flaps of a cardboard box cut to make the shape of Thomas the Train
  2. Add a curved piece of cardboard for the train roof.The top flaps of a cardboard box cut to make the shape of Thomas the Train, this time with a roof added to the back
  3. Add the extra box lid around the bottom for the base of the train.Cardboard box train shape with this red base box added to the bottom
  4. Paint your train.Cardboard box train shape painted blue with a black roof
  5. Add the train markings and decoration with paint or by designing and printing from a computer.Piece of paper with decorative red rectangle and half circle and yellow number 1 to cut out and paste to the side of the train
  6. Measure and cut the train's face.Round cardboard base attached to the front of the train shape
  7. Use paper mache to make the face 3D.Lid of the round cardboard box with paper mache over it to make the 3d shape of Thomas the train's face
  8. Spackle the paper mache to make it extra smooth.Paper mache train face with smoothed spackle on top
  9. Paint and attach the face.Closeup of the cardboard train's cute face
  10. Cut the 4" round box lids in half, paint and glue on as wheels.Blue half wheels with black spokes for the train
  11. Glue on webbing or ribbon as straps to hold the train on your child's shoulders.View of the back of the cardboard box train costume

Notes

  • Don’t worry about the exact dimension of the boxes I used, find one that fits your child and go from there.
  • Many people have recreated this Thomas the Train costume without the 3D face. I promise, it still turns out extremely cute, just find a picture of Thomas’ face and print it out at the right size!
  • If the weather forecast is questionable, you might want to give you Thomas the train costume a little spray with some poly or other clear protectant. Or have your little one wear a clear poncho on top!

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© Cassie May
Project Type: Halloween Costume / Category: Crafts

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Comments

  3. Fabian says

    Esta muy interesante y barato de hacer…

    Lo que se me ocurre que ya una vez que pase el evento, se puede poner nuevamente el fondo y entonces usarlo como caja para juguetes =)

    It is very interesting and cheap to do …

    What occurs to me that once the event passes, the box can be put back and then used as a toy box =)

    Reply

  4. Kate says

    Can you please tell me how heavy it was? I’m worried my 3 year old will complain about having to wear it. Did yours?

    Reply

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    Reply

  7. Stephanie spurlock says

    Thank you so much for the tutorial! I made my son one for Halloween this past year and it was a hit! My 3d Thomas face didn’t work out well though so it had to be flat lol

    Reply

  10. Vanessa says

    Hi, I know this is a super old post but I have a question for you–what did you do with the entire bottom of the box? Did you cut out the flaps? My Thomas structure is about 99% done, but I just realized my son won’t be able to stand in it unless there’s a hole there. Thanks!

    Reply

  11. Jenna says

    I am making this for my son for this year. I was just thinking how you made this 4 years ago and how your little guy must be all grown out of Thomas now! Anyway, thanks for this. I hope it turns out as good as yours!

    Reply

  15. Annalise Malin says

    I’m 20 and attending art school and this design will help me create my own adult version of this for my schools Halloween contest. 2017, I know right that was a long time ago. Small artistic adjustments but the same idea. Thank you. I’ll be sure to update this when it happens.

    Reply

  16. Heather says

    Thank you SO MUCH for this. My son is obsessed with Thomas and this literally made his dream come true. I love to paint and create things but building a replica of something so beloved is daunting. This was the push I needed. I only really changed a few things: I put a bit of batting in the “toot”, I nixed the extra box on the bottom and used a strip of red paper (my box as already too wide), and I moved my wheels all the way up onto the box because they kept popping off. OH and I covered the whole thing in a few coats of Glossy Mod Podge which REALLY brought it to life.

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    Reply

  18. carmen says

    hi,its is beauty,you can show me which spackle do you use for the face,please!!! I want to buy the spackle correct please!!!!

    Reply

  21. Amy says

    This is amazing. My son LOVES Thomas!!! I am thinking I might make an attempt to recreate this.. I know you said a few years ago that your son loved it and you were not willing to sell it then. Is that still the case? Because I would love to buy it from you if it were available.

    Thanks 🙂

    Reply

  22. Crystal says

    I tried this last year for my then, 3 year old. It was perfect! Your instructions were great. I chose to use home made paper mache and found a light sheet rock paste that worked perfect to form the face. I too, pay attention to the details. It turned out great. I wish I could post a photo to show you how it turned out. Now with them getting bigger, we’ve kept it, but should probably sell it since some may not have the time or want to take the time to make one by hand. Either way, it was a great idea.

    Reply

  23. Heather says

    What did you use to join the cardboard together where necessary? Such as when you added the roof supports and then the roof?

    Reply

  25. Dee-Dee says

    This is a great tutorial – thanks for sharing! I am using it to make a black locomotive for a store Christmas window display (à la Selfridges London) – minus the Thomas face and the opening for the costume-wearer – and wondered how you adhered the various pieces to the box, such as the roof, the front panel, etc. Did you just use hot glue for that? Thanks!

    Reply

  28. Rachel says

    I’m making this for my son’s costume this year and I’m almost done. Two quick questions: What did you use for straps and where did you hot glue them in the back? Thank you!

    Reply

  30. Eliane says

    Thank you so much, Cassie. And what about the eyes – is that foam? I hope my Thomas looks a tiny bit like yours 🙂

    Reply

  31. Eliane Almeida says

    Amazing work, Cassie! Quick question if I may: did you paint Thomas’ face in grey? I see eyes are white, but just wondering how to make the face grey: paint? Thanks very much, Eliane

    Reply

  32. BJ says

    Luckily, I am an architect and can follow your great directions/pics. I may not go as far as you did on the 3D face, the mom said that was ok. I have an idea of getting a color photo of Thomas’s face blown up at the print/copy store if the price is rt and image clear and glue it to the round bx. I also found some very large plastic eyes w/ the moving black pupil at Walmart I’d like to use on the face. I do have 2 questions: to get the proportions rt.. “what was the size of the Rd bx you used for the face?” … 8″ diameter or 10″ ? and …it looks like you just used the lid of the boot bx for the base? …or did you cut dwn the bx part to a depth of ? 3″ ? Thanks in advance.

    Reply

  33. Katie says

    I used your directions to make a Henry costume for my son last year and he is INSISTING I make him a Thomas costume just like it for this Halloween. Thanks so much for your directions! Everyone loved it last year, so I’m sure they will again this year.

    Reply

  35. Rebecca says

    Awesome! Thank you for your creative mind and sharing! I am struggling with the arch piece that is part of the roof. I was wondering if you created this freehand or used a tool or template? Thanks!

    Reply

  36. Rachael says

    WOW you did an amazing job! I made my son a Kristoff costume last year, which was fairly simple( along with a sled over our red wagon), but this is great. We are going to disney for Halloween though and i think it would be a feat to get this to Orlando otherwise i would try it, becuase you gave fabuloud instructions!! Keep it up girl!!

    Reply

  38. Emma says

    Thank you for your super helpful guide, i made one for my son! I am in no way artistic so was extremely pleased with my effort and my son loved it

    Reply

  39. Kerri says

    I love the costume and I have a few questions for you in regards to your costume? If you could reply on here or email me please, thank you!!!!!

    Reply

  40. Sara says

    Hi,
    Great costume! You are very talented and creative.

    I was wondering how your son got in and out of the costume if the straps were hot glued onto the box. Does the whole thing lift onto him and off of him over the top? I just worry about not getting the straps stable enough for my 4 year old to make it through trick or treating. And how to make it fit him right.

    Thanks!

    Sara

    Reply

  41. Gabrielle says

    I will be attempting to make this over the weekend for my sons Halloween school parade. If I get it together I will look like a supermom!!

    Reply

  42. Meggers says

    Thanks so much! I made one for my son for this Halloween. We already went to a costume party this weekend and it was a HUGE hit! THanks for your tutorial!

    Reply

  43. Stephanie says

    How many coats of acrylic paint did you have to use. I’ve done two coats, and the cardboard is still showing through. My son is sure excited! Thanks for the ideas!

    Reply

    • Cassie May says

      I want to say I did two coats. But I’ve found that it really depends on the brand of paint. If your box has a lot of markings on it, sometimes it helps to put a coat of dark gray or black under the blue just to even things out. 🙂

      Reply

  45. Debra Myers says

    Hi Cassie,
    Love, love, love, this, & my boys will too. I’ve always been a crafty kind of person, (although I think that your train goes above & beyond crafty !). Probably more overachiever!! I don’t think I will have any trouble with it. I was wondering if you had any more designs for cardboard box costumes. I have three grandsons. Thanks so much.
    Debra Myers

    Reply

  46. Stephanie says

    This looks so awesome! My son is also excited to be Thomas for Halloween. I think you said that you cut off the flaps from the bottom, I’m just wonder how you attached the platform/boot lid? Did you just glue around the bottom edge and stick it on?

    Reply

  47. Eric says

    what did you use the shoebox for? is it for the roof? that is the only part i am having difficulty figuring out.

    thank you so much for posting this.. if it works out my son will love it

    Reply

  48. Christina says

    What did you use for the eyes? Is it some sort of foam pieces? I figured out everything else but that part. Thank you!

    Reply

  49. Emily says

    I am almost done wit but was wondering if you remembered what font you used for the number. I’m having a heck of a time finding one that is similar.
    Thanks for everything! My nephew is going to love this!!!

    Reply

  50. miranda says

    this was a great idea, thank you for sharing! im making this now for my son. what glue did you use for attaching the boxes used for the wheels and face? hotglue?

    Reply

  51. Kylie says

    Good Morning, I love this Thomas Train, I will be making it for my 3year old son for a school project. However I agree with Theresa the base box looks smaller than the body box, how did you get that to work?

    Many thanks

    Reply

  53. Theresa says

    I plan on making the Thomas for my 3yr old son. I understand all but the platform how did you do it the boot box looks smaller then the other

    Reply

  55. Sarah Jerome says

    Love this costume! Where did you find the adorable cap and overalls??!! Such a cutie! Thanks for posting great ideas!
    Sarah 🙂

    Reply

  56. Melanie says

    This by far the most creative costume tutorial I’ve ever read and I enjoyed your sense of humor. I too have that design challenge twitch… tell me it’s not possible and I’ll have to prove you wrong! Love it! I can’t wait to try this when my lo is older. There’s just something about those trains that have those boys hooked! 🙂

    Reply

    • Cassandra May says

      Hi Judy,
      I just used regular acrylic craft paint, and no, I did not prime the cardboard. Although if your cardboard has a lot of markings that you want to cover up, it probably wouldn’t hurt. 🙂

      Reply

  58. Laura says

    Thank you for posting such detailed instructions! My 3 year old daughter is a Thomas fanatic, and I do not like the costumes available for purchase. This will definitely be a challenge, but between myself and my engineer husband, I think we can pull it off! (I hope it doesn’t rain this Halloween, lol) I have this bookmarked and I am so grateful that we can use your model! I hope ours ends up half as nice as yours, though I am not holding my breath, lol. Your son is absolutely adorable!! GREAT job with this costume!!

    Reply

      • Laura says

        ACK on the rain! I’m working on this now. So far so good, but I am worried about the number and side details! And the paper mache! We will muddle through. I will definitely take a picture. And hopefully mine won’t be one of those Pinterest “nailed it!” pics, lol!

  59. Krisy says

    This is amazing! Can I buy it from you? My son wants to be Thomas and your costume looks professional! I’m not sure I have the time to do this and make it look as good.

    Thanks!
    Krisy

    Reply

  61. Belinda Seger says

    Hi, Thank you for your reply. I’ve nearly finished actually and cut the lines by hand with a ruler, they aren’t as neat as I wanted but still it’s all looking good. He’s wearing it tomorrow so I will definitely send a picture on…not sure who’s more excited me or him!

    Reply

  62. Belinda Seger says

    Hi I love love love your costume!!!! I and am going to make one this week for my thomas obsessed son! just wanted to ask about the red lines you did on illustrator and if you had the document you could share please???? also i assume you printed on a3?x

    Reply

    • Cassandra May says

      Hi Belinda!
      I’m sorry, I don’t have a document. When I was making it I just drew it in illustrator real quick and then didn’t save it because I didn’t think I’d be needing it again. Wish I had thought ahead to this question! You could easily cut the same shapes out of construction paper though if you want to go that route! I’d love to see yours when it’s done!

      Reply

  63. Katie @ The Casual Craftlete says

    Wow…this is an amazing costume! You did just a wonderful job. My daughter loves Thomas. This will be one of my features from the blog hop so much sure to grab you ‘featured’ button on Sunday. Thanks SO much for sharing at the Frugal Crafty Home Blog Hop!
    Katie

    Reply

  65. courtlady says

    Your design is clever but what I really love is the smiling, happy boy! He is so happy and so proud! Keep these pictures, someday the grown man will say, “Hey Mom, do you remember the train costume you made me? I wish my kids could see it.”

    Reply

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