No problem! I am sorry I didn't get back to you sooner. It was a busy day. Anyway- since I am posting here I might as well give you my ideas. Okay- there are 2 ways to do this. One way would be to get a sweatsuit for each boy in the Pluto color. This may be hard to do locally but if you go online to perhaps Hanes or Russ athletics you may just luck out. If you go that route there is very little to do. You can glue on the sweatsuit anything you need to with clear fabric glue. They sell it at JoAnns, AC Moore and Michaels. It smells so bad (think really strong nail polish remover) but the smell goes away once it is dried and it dries clear and it is washable. I have used this for so many things and it works great. Then you get a baseball hat. You need to get fabric that matches the sweatsuit. I like to use the soft fleecy stuff that they sell at JoAnns. Cover the hat with the fabric using the glue to secure it. You may have to use clothes pins to keep it in place until it dries. Then take felt and cut out Pluto's eyes and ears and glue them onto the hat. You can also make a felt dog collar but I would probably just put a black turtleneck (it would look like the collar) on the kids and glue felt letters to spell out Pluto on it because I would be afraid of them choking with the dog collar. Pieces of felt are really cheap. You just draw the letters on with a Sharpie and cut them out. Don't forget to make a tail with some felt either. You could also us a long black shoelace glued onto the butt.
Another way to make the costume is to but a couple of yards of material in Pluto color. Again, I like the fleecy stuff. Now I am not a great sewer but I do have a machine and can use it. Keep in mind that you can either glue it together or sew it. The glue I mentioned earlier is super strong so your costume will not fall apart. Anyway- what you do is take a sweatsuit from each child in their size. Lay out the material and put the sweatsuit on top of it to use as your pattern. Make sure to double the material since you need 2 sides. With a marker trace around the whole sweatsuit. Be very generous though because you want it to be very loose. Cut it out and either glue together the 2 sides or sew it together. Cut it from the neck in the back down to about the butt so you can put it on the child. Put velcro tabs on the back so you can close it up after it is on. Make the hat with his eyes and ears, add the tail and you are set.
It is a really easy costume. I hope this helps you a bit.
Jennie