Here are the finished costumes.
The Ewok headdresses are made from:
Headband, Fur and suede fabric – Sew ears (just two ear shapes together and turned) and hand sew/glue to headband. Drape fabric over head and cut holes where ears will poke through. Carefully cut out face hole (start small, can always widen the hole) I just brushed glue on the edges to stop fraying.
Add detail – Feathers, model magic (molded the skull over tin foil then removed foil)
Old Navy brown performance fleece – They have Tall sized which is great for my 6’4″ ewok husband.