I know it might be a bit early for some of you, but fall is just around the corner which means it’s time to start thinking about Halloween costumes! If your kid is like mine and have train on the brain, then you’ve come to the right place. By now you know that my son is obsessed with all things train.  From the time he wakes up to the time he goes to sleep that is all he talks about.  So, last year for Halloween, I decided we would try and make him a custom train engine costume out of cardboard.  To be honest, it seemed a teensy ambitious and I had my moments of doubt since this was our first attempt at a DIY Halloween costume.  But we decided to give it a try anyway and I am happy to report that once we got started, we were surprised at how easy it was to put together.  Best of all, it gave my little guy and I a chance to bond together and have fun.  Being able to create memories with him is always a win in my book. 

Today, I am excited to share Part 1 of our 3-part train Halloween costume series.  Below I am going to walk you through all the steps including instructions and tips that we used to make this cardboard box into a cute Halloween train engine costume.  #boxtume

Without further ado, let’s get started!

Step 1: Gather materials

Large cardboard box

Small cardboard box

Tape 

Scissors

Box cutter

1 can of black paint

1 piece of paper plate

Paintbrush

Red tape

Yellow tape

1 piece of black tissue paper

Red paper

Yellow paper

Glue

Glow in the dark paint

Printables/Stencil

Velcro

Step 2: Make the train engine & wheels*

(*Side note: I forgot to photograph the very beginning portion of this tutorial but it’s really pretty easy).  

I modeled the train engine costume from this tutorial that Little Rubif published a few years ago.  She walks you through how to make a Percy costume out of a diaper box and the concept is pretty simple.  So, I adapted her idea to come up with our own version.  

To start, you will need 2 cardboard boxes.   One big one for the body and one small one for the cab.  Next, I measured my son to determine the length and width of the opening for where he will stand inside.  Then, I cut out the opening using a box cutter.  

Afterward, I had the little guy traced just the bottom portion of a small plastic circle on the bottom panel of the box for the wheels.  He did three on each side.  Then, I cut off the excess cardboard.  Repeat on the opposite side*.

Next is to add the boiler.  To do this, I used a small strip of leftover cardboard.  Before cutting, I bent the strip of cardboard so that it curves and made sure it lined up around the front of the box.  Once we were happy with the alignment, I stuck it on the top of the front of the box with tape.  After that, we attached a paper plate to the front to cover the hole and voila, instant boiler! 

Once this step was done, we affixed the smaller box to the back of the bigger box with tape to create the train cab.  

At this point, my son and I should have already thought about adding the smokestack and buffers on the train engine car as well.  However, we didn’t do this until after Step 2 was completed.  But I wanted to mention this step here, so that you won’t make the same mistake that we did.    

Step 3: Paint

Once you have your general train body shape, you can paint it or decorate it with the color of your choosing.  Since we were going for a dash of spooky, we chose black.  We only needed one coat and it was enough to cover the finish of the cardboard boxes and tape well.  Then, we set aside our train engine and let the paint dry completely.  

Step 4: Figure out the details

While the paint is drying, figure out what designs you want on your cardboard train engine.  So, depending on what type of look you are going for; you can do as little or as much as you would like.  For us, I wanted my little guy’s cardboard train engine Halloween costume to be cute, fun, colorful, and unique.  Therefore, we added a lot of features to make sure that it stood out from the crowd which not only included cute pumpkins, adorable spiders, and a playful personality, but glow in the dark paint as well! #becausewhynot

Step 5: Print, color, and cut

After you’ve figured out what designs or details you want on your cardboard train engine, it’s time to print, color, and cut! 

This process was done per image and is really the most time-consuming part of this DIY cardboard train engine Halloween costume because it can be tedious.  But honestly, it flew by, and it was even faster with my little bestie involved in the process! #yayscreenfreefun

In general, except for the numbers, to do this, my son and I searched for free template or coloring pages online to use.  Once, my son picked the images that he liked, I then printed them on regular paper.  Next, I had my little guy color in all our images.  After he finished this step, I took over and carefully cut out our images with scissors.  We repeated these steps until they are all done.  

Step 6: Assemble the train engine

Next, once the box is covered in paint and completely dry, start adding your designs or details to your DIY cardboard train engine Halloween costume.  And for these next steps, unless it involves tape, just run a little of glue all around the paper and stick it down.

First, let us start off with the wheels*.  

(*Side note: Since the template was for a full wheel, I trimmed it down to our needed size).  

Secondly, attach red tape to the sides of the train engine to create visual interest as well as windows in the train cab.  Of course, you can customize this in your child’s favorite color(s), but in this case we chose red, my son’s favorite color.  

Next, move on to the numbers*.  Apply the red numbers first then the yellow.  Do make sure that they overlap so that it adds contrast to your train engine.  

(*Side note: The numbers weren’t a free image online.  Rather we used one of my scrapbooking stencils to trace out our numbers on red and yellow paper).  

Then, it’s time to add some cute pumpkins and adorable spiders!

After that, we used red and yellow tape to add more details to the costume.  Alternate between the two colors.  Basically, you want to cover the top of the train engine box.  

And let’s not forget about the smokestack, just add a black tissue paper.  You could glue it down for added security, but unless it’s super windy where you live, it’s not necessary.  

Of course, a haunted train isn’t complete without a personality and there’s nothing quite like a pair of printed googly eyes and a goofy smile to do just that! It’s such a fun and easy way to add a bit of playful yet spooky look.  

Step 7: Add glow in the dark paint

For a unique touch, the glow in the dark paint was a last-minute addition, but I am so glad we went for it.  While you can certainly choose to paint your entire train with glow in the dark paint, we only chose to paint the details that we wanted to show up in the dark during trick-or-treating such as the face and the numbers.  Not only did it give our train engine an eerie glow that is perfect for any Halloween event, but I just love the effect and wow-factor it gave my son’s costume! 

Step 8: Add straps

Lastly, you need to add straps*.  We used Velcro but you can use a ribbon or fabric strap – you decide! To do this, have your kiddo try the train engine costume on first so you can see where to place the straps and how long to make them.  Afterward, attach them to the cardboard train engine with glue or tape.  TA-DA! 

(*Side note: You guys, I messed up! I totally forgot all about the straps and didn’t realize they were missing until I wanted pictures.  In my opinion, the straps were probably the most challenging part of this DIY Train Engine Halloween costume because I was tired, and I didn’t have a clue on what to do.   So, in case you ever run into the same problem, here’s a little rundown on how we solved this issue.  First, I asked the hubby for help.  And being the engineer that he is, he used a screw nail to pre-drill the hole in the center of the cardboard and Velcro straps to attach to the box.  Once we were happy with alignment, he replaced the screw with a nut and bolt to secure straps to our cardboard train engine.  Repeat on the other side).

There you have it, an adorable and wearable DIY cardboard train engine Halloween costume for your little one.  

Next up, part II of our train theme costumes featuring the coal car! 

What is your kid dressing up as this Halloween? 

For more Halloween Ideas:

Cop & Robber Halloween Costume 2020

Baker & Cupcake Halloween Costume 2021

Monthly Ramblings #6: Halloween Edition

*Disclosure: This post contains affiliate links.  If you click through and make a purchase, I may receive a commission (at no additional cost to you).  

**Additionally, some items linked above are not the exact item shown because it is either old or sold out, but I linked similar items for those that are unavailable.