When Instructables user mrcrumley noticed his four-year-old son was pretending his frisbee was Captain America’s shield, he realized he needed to make him a Captain America costume for Halloween. Steve Rogers has never looked so adorable. Mrcrumley was able to hunt down many of the materials at a thrift store, and he was resourceful. He found a pair of duffle bags and stripped them to provide the buttons, snaps, straps, etc. that he needed for the costume. He made the mask from papier mache using this process:
To make a mask pattern that would fit well, I wrapped my son’s head in plastic wrap and applied little pieces of tape (paper-mache-style) to the plastic. Then, I slipped it off his head and cut it out into pieces that would lay flat. These pieces became the patterns for the mask. Then, I sewed together the pieces into a rather fashionable mask (if I do say so myself).
Pressing the mask’s seams was a bear (particularly the eye-holes). And in the end, I had to resort to hot-gluing the seams to the underside of the mask. This was the only way I could keep them from poking into my son’s eyes.
Read more at Instructables.