I try to come up with Halloween costumes for our kids each year. This was much easier to do back when I got to pick what they were going to be. As they have gotten older their tastes have gotten much more interesting for me to fulfill.
I am not much of a seamstress. I have generally sewn Christmas stockings, and a few other simple things. A few years ago I made my first attempt at sewing a costume. My youngest son wanted to be James the Train from Thomas the Tank Engine. (Well, he wanted to be Thomas, but they didn't have the right shade of blue felt, so I convinced him to be James instead. I used other costumes I had seen for inspiration. I was satisfied with how it turned out and so was he, but I had set a precedent for making them what they wanted.
The next year #3 asked to be
Jango Fett from Star Wars. (They were all Star Wars Characters that year). I spent hours making
Jango's helmet out of cardboard, glue,
spackle and paint and all the other costumes suffered in the process.
Last year, #3 wanted to be Sonic the Hedgehog and #4 wanted to be Indiana Jones. Both were vetoed. Sonic, because I didn't think I could make the costume and Indy due to the lack of a hat. Instead one was Mario and the other was Dash from The Incredibles.
This year they both made the same request as last year. I prepared to veto, then decided to try.
There are a lot of Indy hats out there, but I am not willing to spend $30 for part of a Halloween costume. Instead, I took a plan, floppy wool hat I had, cut the brim down and used fabric stiffener to shape it into an Indy hat. It isn't perfect, but he is happy with it. I sewed a messenger bag for him to use in the costume, and as his Trick or Treat bag. He picked the other clothes out. I'd like to find a better shirt, but he doesn't mind this one if we can't find a better one. All he needs us the bull whip I made out of duct tape for him last year. It's in a box in my closet.

Indy is ready for a fight....
Next came Sonic. I spent some time looking online at other Sonic costumes and didn't love any of them. My son is also somewhat picky about things and didn't like the relatively simple looking hats I found online. I decided to design my own. I made a basic stocking hat, adding other parts to be the spikes of Sonic's hair. Then I attached ear flaps to the hat to help make the area around Sonic's eyes, and to make it look more like Sonic in general. Last came the ears.
For the body, I wanted to just get bright blue sweats, but I couldn't find any the right shade, and they had to match the hat, so I decided to just sew it. This was my first ever attempt at sewing pants. I used a pair of #3's PJ bottoms to make a pattern and went from there. The shirt was the same story. I used an old T shirt for the pattern, but made the sleeves long. The costume is mostly made out of polar fleece, which doesn't fray and is also very warm. It isn't perfect by any means, but #3 loves it and that is all that matters to me. I also sewed some shoe covers so he could have sneakers like Sonic.

Sonic gives the thumbs up on his costume.

A side view of him "running"...
So, that means I am half done this year! I already made a tutu for Baby B's costume (no pics yet) and that means I just have to sew a Link (Legend of Zelda) costume, a ninja costume and #1 is going to be an insomniac and wear his PJs so no sewing there.
What about you? Do you make costumes or buy them?