Blue Oompa-loompa would be really fun! The zipper face looks pretty easy, just google zipper face haha. Oh I know, making decisions is hard!

hehe
DH, wow that sucks!!

taking turns at holidays would be much more fair to your son and you, some people are not interested in fair tho.
My son was lego batman one year with a box and yeah, he fell over, but it was pretty funny, he didn't get hurt. Have to wear snowsuits under costumes here, so a lot of padding. My youngest one year was a knight from Castle Crashers video game, you probably know that one. The head on that thing is huge, that was kinda tricky for him. Yup I know domo, haha that would be cute.
Zombies are always a fun one, and you can get creative with them, and they are not too hard to throw together. Hmm.. there is toooo many choices. Yeah hard.. The year before last I went as melanie daniels from the birds, which was easy, aside from getting accustomed to the fake birds on me, since I really can't stand real birds. Facing fears