This is the first year I've sewn something for one of my boys for Halloween. I'm just not a big Halloween-loving person. (Last year, I did sew Tinkerbell for myself.)
My little guy wanted to be Jake the Neverland Pirate (from Disney Junior). You can buy costumes for this character, but it's so easy to recreate without any polyester! Jeans, a white tee with a slit at the neck, and a vest whipped up from stash fabrics. I self-lined it, so there are no raw edges exposed at seams. I matched up all the raw edges and covered them with yellow bias tape (also from stash fabric). The boots are adult pirate costume boot covers that I resized with a few snips and zips through the sewing machine. A strip of red fabric for the head, and a store-bought sword complete the look.