How to Engineer a Large Cosplay to Fit in Your Luggage

For cons, photoshoots and more, you may have to pack up your costumes and travel with it. This can get tricky with heavily styled wigs, large props and armor. From travel tips to making your costumes break down, this guide has everything you need to know about how to engineer a large cosplay to fit in your luggage.

How to Travel With Cosplay

Traveling with costumes isn't always easy. Wigs, props and bulky armor rarely fits into a small suitcase. Make sure to consider the following tips for air travel, large props and more.

Cosplay Travel Tips

For all traveling such as flights or road trips, these tips can help your cosplays safely make it to your destination.

• Unpack promptly - Once you arrive to your hotel or destination, make sure to unpack your cosplay. This can help avoid wrinkling or damages by getting it out from its confines.

• Bring an iron or steamer - Fabrics will probably get wrinkled or fold lines in transit. Have a portable iron or garment steamer in your luggage so you can steam out the wrinkles once you arrive.

• Bring a repair kit - Accidents happen. Be it on set of a photoshoot or the con floor, you need to be prepared. The repair kit you pack for a con can also be a great aid for traveling incase something gets broken in your suitcase. You'll want things like a hand sewing kit, pins and a hot glue gun in your repair kit.

• Don't over do it - You can only pack and manage so much. If you over pack or bring too many fragile costumes, you may lose track and something could get lost or damaged. Try to be strategic with what you're traveling with so it's only the essentials and what you can handle.

• Use sturdy boxes or padded hard cases - What you pack your costumes and props in is important. Use sturdy boxes, solid suit cases or padded hard cases to ensure nothing gets smashed or broken.

• Ship if needed - Sometimes it's just safer to ship your costume or props to the location ahead of time. There's some things that may not be permitted on a plane through security so you may not always have the choice to travel with some of your props. Be sure to pack your shipment properly and label fragile as needed.

• Use garment bags - Garment bags are essential for your fabric cosplays to help keep them from getting bunched up and wrinkly. They also travel very well and make storing at a hotel easy.

• Make props break down - You can engineer your props to break down into pieces so they're easier for travel and storage.

• Bubble wrap and fill gaps - Don't leave gaps in your luggage. Make sure you add padding or bubble wrap so props and costumes can't be jostled around in transit.

• Measure and plan - Planning ahead of time is important to ensure everything fits safely in your luggage. Measure and plan everything ahead of time so you aren't scrambling to pack an hour before your flight.

How to Pack Large Props

To pack up your large props there's a few steps to take.

• Step 1. Disassemble what you can - If your prop is able to come apart, disassemble it as much as you can before packing it.

• Step 2. Wrap up your prop - Use foam or bubble wrap to protect your props. Wrap up all fragile parts securely.

• Step 3. Pack it in secure luggage - Make sure to pack it into luggage that is sturdy such as hard cases. Then add additional padding so no gaps are present.

How to Make Cosplays Break Down

There's two key ways you make your props come apart. It's by incorporating either magnets or PVC pipes and couplings. You will need to map about how your large props will break apart into smaller pieces and then use the PVC or magnets to be able to assemble and disassemble everything.

• Magnets - You'll need very strong magnets for this option. Using only these is recommended for smaller or more lightweight props and costumes. You can super glue magnets into an indent in your costume so it's flush inside. Then the magnets will connect and be invisible.

• PVC pipes and couplings - PVC pipe and couplings are more durable. You can run pipe through your prop and use couplings to connect them. On one end the coupling should be glued securely to the pipe. The other end shouldn't be glued. The coupling end should be flush inside a hole so it won't be seen. Then the pipe end will connect into the coupling and the pipes will be hidden inside the prop. You need to be sure you pick the right location so the seam isn't obvious.

• Blended option - You can also blend the two by adding magnets to the coupling and free pipe end to make the connection even stronger.

Flying With Cosplays

If you're opting to fly to your destination, use the following tips to help you and your cosplay safely arrive.

• Check airline rules - Airlines and TSA have strict rules about what is and isn't permitted in carry ons and checked bags. Make sure to always check specific rules online before packing for a flight so you don't have issues right before take off.

• Checking bags - Be prepared to check a bag. It's possible what you have is only permitted in a checked bag or you just have too much to bring with you.

• Label fragile - Always mark your luggage fragile so staff is aware to handle with care.

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Conclusion

Packing for a con or photoshoot doesn't have to be a nightmare. With some particle planning and engineering, you can make your larger than life props come apart and be easier for travel.

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Share Your Cosplay Tips and Stories!

Whether you're a seasoned cosplayer or just starting out, it's important to pack your large props and costumes carefully. We'd love to hear your thoughts and experiences with traveling as a cosplayer, so please leave a comment below sharing your favorite thing about it.

Got more tips or advice on traveling with cosplays? 

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