DLTK's Holiday Crafts for Kids
Halloween Costume Pieces
Aprons
This is a ladybug pattern apron, just change the colors and remove the spots as you see fit.
Braiding
Capes and Cloaks
(includes no sew version)
Paper Crown
Gown or Robe
Gun
Hats
Homemade Makeup
Masks
Shields - Paper Mache 
Petal Skirt
Pom Poms