Star Wars Mickey Ears: Han and Chewbacca

We made the coolest Han and Chewbacca Star Wars Mickey Ears in the universe. If you’re heading to Disney, you can easily make these DIY Mickey Mouse ears.

star wars mickey mouse ears on a white wood background with crossed miniature light sabers in the background

Star Wars Mickey Ears

Here at Ruffles and Rain Boots, we have been hiding a secret for a while. Star Wars is one of my favorite movies EVER. There, I said it! And, with the opening of Star Wars: Galaxy’s Edge at Walt Disney World, well, let’s just say that the entire crew at Ruffles and Rain Boots is so excited, it’s ridiculous. 

So, to get ourselves ready for our inevitable trip to Batuu, we made these absolutely adorable Han and Chewbacca Star Wars Mickey ears. I am not kidding, they’re SO CUTE. Let’s get started.

Psst: click here if you’re looking for the Princess Leia Minnie Mouse ears

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You’re busy, I get it. Save this to your favorite Star Wars crafts pin board or share it to a crafty Facebook group.

photo collage of han solo mickey mouse ears with text which reads han & chewie diy mickey ears

Tips to Make these Chewbacca Mickey ears

  • Be sure to print the Han Solo Mickey Ear template here, so that you know exactly what to cut.
  • The Han Solo ear fits together like a puzzle with the flaps of his shirt folding over to give it depth. Don’t fret if your puzzle doesn’t go together perfectly. 
  • If you’ve never cut craft fur before, turn it over and use a razor blade or an Exacto knife to cut only through the fabric, careful not to cut through the fur. You can cut it with scissors, but need to use them as a single blade, not with a scissoring cut.
star wars mickey ears han and chewie

How Do I Make these Star Wars Mickey Ears?

I’m so glad you asked. Below is our written tutorial. If you’re making a Star Wars crafts playlist on YouTube, here is our Star Wars Mickey ears video tutorial.

Yield: 1 set of Star Wars Ears

Star Wars Mickey Ears: Han and Chewbacca

star wars mickey ears han and chewie

We made the coolest Han and Chewbacca Star Wars Mickey Ears in the universe because we're going to be at the Star Wars: Galaxy's Edge when it opens. Whether you're going or not, these DIY Mickey Mouse ears are great.

Prep Time 10 minutes
Active Time 20 minutes
Total Time 30 minutes
Difficulty Easy
Estimated Cost $5


  • 2 Cardboard or Foam Core Board Circles 4-inches in Diameter
  • 1 Black Headband
  • Black Polymer Clay
  • Silver Glitter
  • Craft Felt in black, brown, red-brown, cream, beige, and charcoal
  • Brown Craft Fur
  • Printable Han Mickey Ear template


  • Hot Glue Gun & Glue
  • Scissors
  • Paintbrush
  • Exacto Knife
  • Polymer Clay Sealant


  1. To begin the Chewbacca ear, sketch location and size of Chewbacca’s bandolier and accompanying cartridges onto one of your cardboard circles. lightly sketch chewbaca mickey ears
  2. Form rectangles with black polymer clay to the size of the cartridges you sketched on your cardboard circle.
  3. Roll rectangles of clay/cartridges in silver glitter.
  4. Place cartridges on wax paper.
  5. Bake per the instructions on your clay’s packaging.
  6. Allow to cool before touching.
  7. Seal cartridges with polymer clay sealant and set aside to dry. how to make chewbacca's bandolier from polymer clay for chewbacca mickey ears
  8. Lay headband over cardboard circles and sketch where you want the ears to sit on the headband.
  9. Cut out area of ears that is unnecessary. how to create a template for han solo mickey mouse ears
  10. Trace the new shape of the ear onto the back of the brown craft fur, taking care that the fur will lay the way you want it to when mounted to the ear.
  11. With exacto knife, cut out ear shapes from the brown craft fur. photo tutorial of how to cut faux fur for chewbacca mickey mouse ears
  12. Hot glue ear shapes of brown craft fur to the front and back of the cardboard cut out. Take care to glue around the edges, keeping the edge of the fur fabric from showing. how to make chewie mickey ears photo tutorial
  13. From the black craft felt, cut out a ½-inch wide strip, or larger, dependent on your sketch of Chewbacca’s bandolier.
  14. Wrap this around the fur-covered ear in the approximate location of your sketch and hot glue in place.
  15. If cartridges are dry, hot glue them in place on the bandolier to correspond with your sketch. Set aside the Chewbacca ear. how to make chewbacca mickey ears photo tutorial
  16. To begin the Han Solo ear, trace the cardboard circle onto the black craft felt and cut out around this shape, leaving about ¼-inch extra fabric.
  17. Hot glue this black craft felt circle onto the back of the cardboard ear, wrapping the extra felt around the edge of the cardboard and around to the front. Take care to glue the edge down. Set aside.
  18. Cut out the pieces on the provided template.
  19. Trace each cut out piece of the template onto the corresponding color of craft felt.
  20. Cut out the traced pieces of craft felt.
  21. Hot glue each piece to the corresponding location on the cardboard cut out. Keep in mind that these pieces fit together tightly, like a puzzle, but the collar pieces overlap other pieces to provide depth, and to provide a place for “expansion” if your cardboard cutout is a little differently shaped than mine. how to make han solo mickey ears photo tutorial
  22. Retrieve the Chewbacca ear and place both ears onto the headband where you want them to be.
  23. Hot glue the two ears in place on the headband, taking care to hold them firmly until the hot glue is completely cooled. Enjoy! chewbacca and han solo mickey mouse headband on a white wood background with mini light sabers crossed in the background


For more fun Star Wars craft ideas, visit

Did you make this?

Please leave a comment or share a photo and tag me @rufflesandrain

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photo collage of star wars mickey ears headband or hat with text which reads star wars heroes diy mickey ears

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