I didn't realize this was an old thread but, I got off easy this year as far as making costumes for Halloween.
this year the boys said they wanted to be Si and Willie Robertson from the 'Duck Dynasty' cable TV show.
I said fine as that would only really require coming up with something that looked like hunting clothes (off to the thrift store....) but, what about the beards?
All the Robertson family men that appear on the show (and several others on the show) have their enormous trade mark beards so, any costume would need a costume beard as well.
A check of the seasonal Halloween shops came up with nothing but, a friend of my wife said that they an actual licensed costume product could be had at W#l-M##t so I allowed them to shop there for their costumes just this once.
They both look pretty good. Maybe I'll even post a picture.