This year my son picked Mickey Mouse as his costume and every year we have to incorporate a costume for the wheelchair. We start with a heavy cardboard form that slips right over the wheelchair. We then layer 2″ foam core on top of the cardboard. We layered outwards for each piece that we needed, sanding the foam core to take the shape of each piece.
Painted and chalked the seams. Used sheets of duck tape for silver appearance on windshield and lights. Lights were tap lights that actually worked. As usual our furry family member was incorporated as part of the costume and went as Pluto.
There you have it! Mickey Mouse and Car Wheelchair Costume. We love Halloween!
Related costumes:
Incredible Topiary Mickey Mouse Costume 
Disney 2K Hip Hop Mickey and Sassy Minnie Couple Costume 
Wreck-It Ralph Family Costume with Sugar Racer Wheelchair Costume 
Scary Mickey and Minnie Mouse DIY Couple Costume 
Vintage Mickey and Minnie Mouse Costume 
Coolest Home Made Mickey and Minnie Deadmau5 Costume (MickeyMau5) 
Coolest Homemade Mickey Mouse Costume 
Awesome DIY Vanellope von Schweetz Wheelchair Costume
I have a couple of questions about how you made the awesome costumes for your son!
Are you using foam board such as this http://www.walmart.com/ip/Elme… and gluing the boards together to achieve the 2″ thickness?
What type of glue did you use to glue the boards together?
What type of sandpaper did you use to form the foam boards into shapes?