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Transformer Rescue Bot Costume (DIY)

Well in keeping with our theme of the year (Transformer Rescue Bots) my kiddo chose a Halloween costume that wasn't available in stores. I was surprised to find that there were several options available for purchase with Rescue Bots just not the particular hero we were looking for.

So for a couple of days weeks I thought about how I was going to put this costume together, make it warm (since it's typically coat wearing weather where we live), and keep it comfortable while allowing him easy access for potty breaks. These are all legitimate things to consider for small kiddo's.

I finally decided to construct the whole costume from fleece and I used quilt batting on the interior.

Let me apologize for the poor quality photos - I just snapped a few with my cell phone not anticipating a blog post. But after placing 2nd in a nationwide online costume contest I had second thoughts - and well I blogged. :)

The body of "Chase" the Rescue Bot is constructed like a poncho. The logo is made of felt and each yellow piece was cut by hand and glued to the red emblem with fabric glue. Underneath the poncho he is wearing a thermal and a white long sleeve t-shirt. And blue kid gloves picked up at Wal-Mart. The arms are 4 piece construction "cuffs" that have a small piece of velcro inside and holds them to the sleeves of his shirt. Each cuff sports the words POLICE (embroidered letters and fabric glue) and also holds his loud speaker and siren. His feet cuffs are also 4 piece construction (I made 4 panels and then attached them together) adding the yellow lights and made them cover his shoes. He is wearing thermals and thick gray jogging pants (from Wal-Mart). The helmet - I hate to say in case you are looking for one - was a yard sale find for $.50 and YES the lights on top flashed and worked! To the should of his poncho and side of his leg cuffs I attached "tires" which were constructed of firm felt sheets with interior wheel glued on. I then hand stitched those into the appropriate location. The last addition was the light bar on his back (which he insisted on!). It was also constructed from the firm felt sheets cut into four pieces and then all stitched together. This was all done by hand - then used velcro to hold it to the back of the poncho at shoulder height.

This costume was a huge hit at every event we attended and he got lots of compliments everywhere. We even decided to send a picture to D.C. Douglas who does the voice over for Chase in the Rescue Bot animated series.

If you have to construct a Rescue Bot Halloween costume I hope you have find some helpful ideas here. Thanks for reading.


  1. Any chance you'd be open to selling this costume? I LOVE yours so much more than the store versions. Also, I am super pregnant with baby 2 and not talented like you. What size is it? Thanks!

  2. My three year old wanted to be Chase for Halloween. Thank you so much for your blog post and pictures - I was able to use it as a guide to make my son's costume, and he is still SUPER excited about it!! He has a friend that loves Heatwave, and I am going to give that a try next!

  3. Hey, I sent you an email - my email is - I hope you received it!


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