My husband and I dressed up as characters from Castaway. My husband was Chuck (played by Tom Hanks) and I was Wilson (played by a volleyball). Wilson started as an inflatable ball and after 6 layers of newspapers, glue, and flour, and lots of paint, it ended up as my costume. My husband wore a beard and hairpiece, and along with his washboard abs and a FedEx box, he ended up looking pretty much like Tom Hanks by the end of the movie Castaway.
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