I rocked Castle in his car seat with my left foot while peddling the sewing machine with my right foot for this costume.
I made a pattern for the hat following Castle's pilot cap. I lined it with freezer paper for stiffness and fleece for warmth. It's kind of chilly in wet rainy Vancouver. I used freezer paper because, well, I was tired. I didn't want to go out to buy interfacing. He's only going to wear this once, so I thought, why not? I can iron the freezer paper right onto fabric.
His robe is made of fleece and I used his house coat as a pattern. Fleece is so great for costumes, I didn't even hem any of it because it doesn't fray. When one is a sleep deprived person, one looks for short cuts to make life easier.
He held the light saber all on his own and waved it around.