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Sewing & Craft Alliance


Sewing & Craft Alliance

Halloween Projects

Project provided courtesy of:

Jo-Ann Fabric and Craft Stores ©

Jack in the Box Costume

Jack in the Box Halloween costumeBe the hit of the Halloween parade in this delightful "pop-up" costume! Turn a plain brown box into a unique, almost-no-sew show-stopping hit.


  • 10 yards 60"-wide orange felt
  • 8 yards 60"-wide purple felt
  • 1 cardboard box, 22" square for body
  • 1 22" x 22" piece of cardboard for lid
  • 1 8" Styrofoam® ball
  • Gold spray paint
  • Stuffing for hat
  • Elastic
  • 4 yards 1"-wide woven strap for webbing
  • Thick tubular sculptor's wire for handle
  • Craft glue or hot-glue gun and glue sticks
  • Packing tape or duct tape
  • Large safety pins
  • Velcro® brand self-adhesive tape
  • Sewing machine, needle, thread, scissors, rotary cutter, mat knife, pencil or marker
  • Suggested embellishments: Gold rickrack, colored gemstones, bells, sequins-by-the-yard, black fringe, gold glitter, gold wooden buttons, mini jingle bells
  • Pattern for hat

Directions For Body

  1. Box: Fold in top and bottom pieces and tape to inside box with packing tape.
  2. For shoulder straps, cut 2 slits in front box panel. Measure 5" from box top and 8" from left edge. Cut opening wide enough for strap (" x ").
  3. Cut second opening 2" down from first opening, 7" from top.
  4. Repeat on right side of box and back box panel.
  5. Cut webbing in half. Thread one end through inside top slit on front left, and feed through bottom slit. Pin end to strap. Attach other end through slits in back panel. Repeat on right side. Adjust straps and pin to fit child's height.
  6. If desired, for additional support, apply tape over inside and outside slits.
  7. Lid is 22" x 22" piece of cardboard. We used one panel of a second box.
  8. For lid top, cut orange felt to size of lid, adding 2" on 3 sides and 5" to the end that meets the body. The 5" end will act as part of the hinge for lid.
  9. Adhere orange felt to box lid. Fold edges over 3 sides of lid to inside. Let 5" hinge piece hang.
  10. Measure and cut purple felt to fit inside lid with no fold-over pieces. Leave a 5" hinge piece on the bottom as above. Glue purple felt, covering orange felt at the edges.
  11. Cover outside box with orange felt, leaving enough to fold over edges to inside.
  12. From purple felt, cut large diamond shapes and glue around box and on lid.
  13. Glue hinge pieces to back top of box. Secure with pins or clips until glue is completely dry.
  14. Glue fringe, sequins, gems, rickrack and more to decorate box; see photo for ideas.

Instructions For Collar

  1. Cut 24" x 60" pieces of orange and purple felt.
  2. Fold in half lengthwise and cut eight 6" x 12" triangles in each color. Fold should be at wide part of triangles.
  3. Approximately " down from fold, stitch a channel.
  4. Alternating colors, string triangles through channel with 12" piece of " elastic. Secure elastic on both ends. Pin or use Velcro® brand tape to attach collar around neck.
  5. Instructions For Cuffs, Hands and Feet
  6. Cut 16" x 60" pieces of orange and purple felt.
  7. Fold felt in half lengthwise and cut 10 4" x 7" triangles of each color.
  8. Stitch a channel for elastics 3.4" down from fold.
  9. String triangles on elastic to fit wrists and ankles. Secure elastic. Embellish tips of triangles with bells or pompoms if desired.

Instructions For Hat

  1. Enlarge pattern piece to 200%.
  2. Cut 3 pieces of each color felt using pattern.
  3. With straight side at bottom and hook (or point) toward the right side, stitch one purple piece (top) to one orange piece (bottom) from "A" to "B" and then to "C."
  4. Repeat for remaining pieces.
  5. Stitch remaining 3 sections to one another from "C" to "D."
  6. Cut 24" x 5" piece of purple felt for hat band.
  7. Fold in half lengthwise.
  8. Cut 6 4" x 7" triangles of each color (no folds).
  9. Stitch triangles to hat band, alternating and overlapping at midpoints.
  10. Sew raw edge of band to raw edge of hat, right sides together. (The right side of the band is the side with triangles sewn on it.) Be careful not to sew triangle points into seam. Embellish as desired.

Instructions For Cape

  1. Cut one 5' x 3' piece of purple felt.
  2. Mark fabric center. Cut hole large enough for head to slip through. Cape should drape inside box to cover straps and box.

Instructions For Handle

  1. Bend sculptor's wire to look like a crank handle. Poke hole in side of box and insert wire. Bend wire down and secure in place with tape. Paint Styrofoam® ball gold and attach to handle.

Approximate Crafting Time: 6 hrs.
Skill Level: Some sewing experience helpful.

Due to seasonal nature of project, supplies are available for a limited time only. Please read all instructions prior to beginning; read and follow all manufacturers' instructions for all tools and materials used. Provide adult supervision if children participate in this and all craft projects. Because Jo-Ann Stores, Inc. and have no control over the use of materials and tools, nor surroundings, during construction of projects, Jo-Ann Stores, Inc. and disclaim any liability for injury, damage or other untoward results. Content of this project sheet is presented in good faith, but no warranty is given, nor results guaranteed.


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