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EPIC Han Solo Vest!!

Added Apr 29, 2011

by dilshadburman

Toronto, Canada






Ideally I would have finished this in less than 12 parsecs…

My boyfriend has wanted me to make him a Han Solo vest, like the one Harrison Ford wore in Star Wars, since before I even bought my sewing machine.
In fact he tried bribing me by saying he would buy me a sewing machine.

When I did buy it, I began making it in secret, hoping to give it to him for Christmas, 2009. When you live with someone though, it’s difficult to get enough alone time to do anything in secret, especially when your sewing table is your dining table.

I steadily worked away at it in bits and pieces when he wasn’t home, cleaning up a half hour before he came home, pulling out another half finished project or pretending to have been sleeping or cleaning while he was out. It was an elaborate operation!
Towards the end I enlisted his friends and got them to take him to out of the way theaters and various other outings so I could get it done in time for his 40th Birthday.

When he opened it at midnight on his birthday all he could choke out was “Wh-wh-wheereee?” before the tears came and then I started crying and it was all a bit goopy for a while.

Once he tried it on, I realised his shoulders are a bit more sloped than I figured. You can see in the last picture how they stick up.
I had expected to make some modifications after I finally had it on him, and luckily I had some hand stitching in the lining by the shoulders. I ripped it open and attached one inch strips at the shoulders to ease the armholes and also tapered the shoulders a bit.

Also, because I started making it so long ago, my sewing skills improved greatly over time. My measurements were a bit off in 2009 so I also added small strips to the side seams between the back and from to ease the garment a bit.

My “special modifications” worked and it’s as close to perfect as I could have imagined.

It’s fully lined with black broadcloth on the inside. This was one of those garments that I wanted to make beautiful, inside and out, so there are no visible seams in the lining. I machine stitched it all on the wrong side, leaving the bottom open, turned it right side out and then attached the bottom edge with hand stitching – an invisible slip stitch I believe. I can’t even adequately explain what I did to get it right.

In the end, his reaction was worth it. It’s my first ever men’s garment, first ever vest/outerwear item and best ever present. I simply cannot top this.

Unless I build him a Millenium Falcon for his 50th….hmmm…

Material Notes

Medium weight twill, cotton broadcloth




Spring, Summer, Fall
Garment Type
Military, Vintage

4 Comments Sign in to add a post

  • Burd_large

    May 21, 2011, 10.38 PMby NeederMoo

    Cool! It looks just like Han’s!

    1 Reply
    • Pixie_redux2_large

      May 24, 2011, 06.35 PMby dilshadburman

      Thank you!

      We recently re-watched the first one and I saw a few inaccuracies, but I’m, super happy with it. He wears it all the time too, which is the best part!

  • Mekidsmountain_large

    Apr 30, 2011, 04.14 PMby Lucha Suarez

    This is amazing! And your story is so cute and touching to go along with it! This is a great menswear idea! I have 4 sons who would just love to rock a hans solo vest, you should do a tutorial!!!

    1 Reply
    • Pixie_redux2_large

      Apr 30, 2011, 10.56 PMby dilshadburman

      Oh my! A tutorial might be tricky! I could do the basics but the lining was really tricky. I’ll try! :)

  • 028_6__large

    Apr 29, 2011, 05.11 PMby puffling

    That is epic!! See, if the Big 4 patten companies made patterns like this, more men would take up sewing! ;)

    1 Reply
    • Pixie_redux2_large

      Apr 29, 2011, 05.34 PMby dilshadburman


      Thank you! I had no pattern. I just looked at lots of pictures and one other awesome lady’s blog post and cobbled it together.

  • P1011343_large

    Apr 29, 2011, 09.35 AMby Adrienne Hendrix

    What a great vest and an awesome gift. I am sure he was surprised and pleased with it. My husband has been asking me for about a year now to make him a simple vest with pockets and of course I just haven’t gotten around to making it. I even have this awesome plaid wool to make it out of. I keep telling him I haven’t found the right pattern that I want to use, but in reality I have been trying to draft my own pattern with not much success. Any pointers on getting started? I want it to be a surprise when I am finished so I will not be able to measure him, guess I will need to snatch something out of his closet to get the correct size. Thanks for the inspiration. Happy Sewing!

    1 Reply
    • Pixie_redux2_large

      Apr 29, 2011, 05.40 PMby dilshadburman

      Thanks so much!

      Well for starters, I’d make up an excuse to get his measurements. My boy is always buying geeky t-shirts online so I often measure him so he knows what size to buy. I pretty much know him top to bottom now. :D

      I also carefully stole from his closet and then replaced another vest he had for basic dimensions and shirts with no stretch for further help.

      The arm hole is key.
      I had no pattern. Just one other person’s blog post to go off of for the pocket details. I think the arm holes would have turned out better if I had a proper pattern, but I’m pleased nonetheless. :)

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