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- | Making Han Solo Costume Vest

Making Han Solo Costume Vest

Han Solo Costume Pants

More in my series of posts about making a Han Solo costume. This time… the Han Solo Costume Vest.

The Han Solo costume vest is black with a lot of specific pockets.

More on Making Han Solo’s Costume:

Getting Started

Making Han Solo’s Shirt

Making Han Solo’s Pants

Magnoli offers a nice one, but I wanted to make it myself and save some money.  I got the Falcon Jacket pattern from Dawn Anderson Designs for Han Solo’s vest. It would require some modification but was a good starting point. There’s a great A New Hope Vest Breakdown thread here on rebellegion by SoloYT1300 (Robert Kohn).  Just in case the thread or images go down, I’ve archived that information here in a zip file if you need it. I have to say, after making it myself, it was a lot of work!

The A New Hope Han Solo Costume Vest is made out of black twill and lined in a thinner black cotton with interfacing in various areas.


Here’s a couple good shots of the vest to get an idea of what you’re going for.



I took the basic front and back pieces (no sleeves, no pockets) of the Dawn Anderson Designs Falcon Jacket pattern and did up a muslin. I had my husband try it on (with his previously made pants and shirt) and I compared the length of his vest to the length of the screen shots of Han Solo. Han Solo’s vest is a little short. It hits perhaps a little above the waist of his pants and in many screen shots it appears to be shorter than his shirt/pants line depending on his posture. I marked with a pen where I wanted the end of his vest to be and roughly where the pockets should be. I very closely watched A New Hope scenes and screenshots to try to get the sizes of the pockets pretty close to what Han Solo’s are. I made sure to leave room on my muslin drawing for seam allowances and empty space between the pockets and the seams.


My pockets ended up being slightly smaller and differently shaped than the ones that come with the Falcon pattern. The Falcon pattern does not have a crescent glove pocket.  So draft your pocket sizes from your muslin and add seam the appropriate allowance. The matching billowed piece pocket parts must also be trimmed to match the new sized pocket pieces. It wasn’t too tough. You can just wrap the billowed pocket piece around your front pocket muslin to see how long it needs to be to accommodate your pocket. The pattern thankfully includes pretty much all the information you need to make the billowed pockets like the A New Hope vest.

Again, please look at the Rebel Legion thread about this vest, you can see which pockets are top stitched and billowed so that you get the details right! Basically, the front pockets are all billowed on three sides (including the crescent pocket). The only exception is the small rectangular pocket which is just topstitched onto the crescent pocket. The large back pocket is billowed on the two sides but topstiched on the bottom.  The “loops” on the back are not one single piece but separate loops.

There is some debate exactly how the flaps work on the lower left front pocket. Some people think there are two flaps or perhaps a hidden pocket inside that pocket (and a second flap on that). It’s so hard to see in the movie whats really going on. I watched the one or two scenes where you can see that pocket partially open and I just can’t tell what’s going on. I decided to just make it a normal pocket.  There’s also not any information I could find on whether the vest has interior pockets. I added one on mine for my husband’s convenience.

Even though I followed the pattern directions very carefully, the billowed pockets were a pretty tough to get even remotely clean/straight. So do this slowly and carefully! The hardest part for me was getting clean corners and really good accordion folds. Clip your corners very carefully and press everything really well. The pattern gives pretty good instructions for this.


Here are the mostly finished pockets without the back loops.


And here is the finished jacket! You can click on the below image to make it larger.


  • Lee

    06.06.2013 at 13:16 Reply

    Thanks so much for sharing this, really useful. Amazing Job, I love it! ♥

    • aimeemajor

      07.06.2013 at 08:13 Reply

      Thanks! I’m glad it’s useful to you! Goodluck with your own costume!

  • Melissa

    27.08.2013 at 12:47 Reply

    Hello! I love this tutorial you’ve done, its SO helpful! I have a quick question. So I ordered the falcon jacket pattern last night, and this morning as I was going through my coupons I noticed a 60% off fabric coupon from Joanne’s. the problem is it expires in two days and I won’t have the pattern in time to see the yardage I need. So I was wondering how much of each fabric (the twill and lightweight cotton liner) you used so my coupon won’t go to waste? Any ball park guess would help! Thanks a ton!

  • Ash

    16.09.2013 at 17:16 Reply

    Thank you, thank you, thank you! I am getting ready to tackle this part of the costume and it’s pretty daunting, but this is a great help!

  • Arthur Denny

    20.03.2014 at 16:36 Reply

    I had a vest from the old fan club.I wore it into the ground and took it apart and made a very passable and practical garment. Id lost the hard copy Id made of my pattern.Years later I started making Star Trek costumes using available patterns but found them suitable as a base for StarWars costumes, I was able to reproduce a vest & Jacket including the Rebel Fatigue Jacket.

  • Amy

    11.05.2014 at 12:44 Reply

    My son and I found your website while we were looking for ideas on how to make his Han Solo costume. THANK YOU!! It helped us a lot! We didn’t do everything “film exact”, but for our purposes, I think we did fairly well!

    (I wish I could post a photo to show you the finished project.)

  • James.F

    02.06.2014 at 16:24 Reply

    Excellent work :) my son (9) wants me to make him a Han Solo (death star escape) outfit and your guide is a great help :) thank you for sharing.

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