With all the current emphasis on nutrition and healthy eating, the day may come when your child announces he needs to dress as an orange for a school play. The trick, of course is creating a spherical shape that a child can take on and off. It is a bit of a challenge, but can be done using upholstery foam.
Measure the around your child’s shoulders. Purchase enough upholstery foam to equal twice the length of this measurement.
Cut a length of the foam to equal the measurement from your child’s shoulders to the knees.
Divide the doubled shoulder circumference into six equal parts. Cut the foam into six pieces, each equaling the width of the divided measurement. For example, if the doubled circumference was 72 in., then each foam piece should be 12-in. wide. Lay each section flat, and trim the edges, tapering them at both ends so that each section is 12 -in. wide in the middle, and about 10-in. wide at either end. This will ultimately help create a spherical shape.
Bevel the long edges of each foam piece at a 30-degree angle, Use a protractor to find the correct angle. The beveling is necessary so that the pieces can be mitered together when glued.
Glue the pieces together: Arrange two pieces so that the beveled edges line up, curving outward. Apply a line of hot glue to one beveled edge. Press the beveled edge of the second piece against the first edge and hold in place for two minutes. Repeat for one additional piece for a total of three glued pieces -- half of a hexagon.
Repeat the gluing process with the other three pieces -- the second half of a hexagon. Glue the two halves of the hexagon together.
Cut two arm holes about three inches down from the top of the hexagon.
Spray paint the hexagon orange. Allow it to dry for at least two hours. Cut a large leaf shape from green felt and glue to the top of the orange.
Wear green pants or tights and an orange shirt under the costume. Slip the round costume over the child’s head and stick his arms through the holes on either side of the costume.