DIY Mr. Potato Head Costume

This post was originally posted as part of The Train to Crazy's Handmade Dress-Up DIY series.  Andrea had oodles of fun costume ideas at her place, so check them out!

Normally I like to be a little secretive about our family's Halloween costumes.  Halloween Night becomes the big reveal!  But this year, I'm letting you in on a little secret.  You get the first glimpses of what we are planning to wear for Halloween 2011.  And guess what?  If you've been around for a little while, you'll probably recognize these costumes!  That's right:  This overworked, underpaid Mommy is recycling costumes from Little Man's birthday party for Halloween.   But Little Man couldn't be happier. 🙂

In our house, it's never a matter of what movie.  It's which number:  Toy Story 1, 2, or 3.  We live and breathe Toy Story!  So naturally, this year we are all dressing up as Toy Story characters.

When Little Man turned two, I threw him a Toy Story birthday party.  You might remember he dressed up like Buzz Lightyear, and we asked all of our guests to dress up like Toy Story characters too!

Our guests were great sports!   To join in on the fun, Mr. Oopsey Daisy and I dressed up like Mr. and Mrs. Potato Head.

I sewed our costumes in 1 afternoon, and they were a piece of a cake!

Are you ready to learn how to make your own?

If you're still wondering what to be this Halloween, I promise you can whip up this costume in no time at all!

Let's get started!

I did a few measurements on my husband to design this A-line shape.  The most important measurements were:

* Distance from shoulder to shoulder

* Waist circumference

* Distance from neck to knee

(Of course you want to add a few inches for a little generous potato-ish shape!)

I purchased 2 1/3 yards of tan felt--that's 84 inches!

Once I folded it in half lengthwise, I had my Mr. Potato Head!  He just needed a little trimming down.  So I followed my measurements and diagram above to cut out an A-line shape.

At the top of the fold, I found the center and cut out a 6-inch semi-circle to create the hole for the head.

Next, I cut out Mr. Potato Head's eyes, nose, moustache, mouth, and ears from felt.  (All the while, I studied pictures of Mr. Potato Head!)  I pinned these carefully onto the front of my Mr. Potato Head.

I sewed the facial features right onto the front.  (Be sure to unfold the felt at this point.)

Then I folded Mr. Potato Head together again and pinned the right sides together.  But before sewing the sides together, I folded up the bottom edge by 1/2 inch to prepare to sew a casing for the elastic bottom.

Here is how I sewed my casing for the elastic.  Once I had that done, I sewed up the sides.

I left the top 13 inches or so unsewn for the arm holes.  Just underneath the arm holes, I sewed in big pink ears on each side--so be sure to pin those ears in as you sew up the sides!

In the back, I cut a 4-inch slit and sewed on Velcro to close it up.  This gives a little breathing room for slipping it on and off.

I happen to think that this Mr. Potato Head is pretty handsome! 🙂

And here is my Mrs. Potato Head version!

So now our family is all set for Halloween.  And I can't wait!

So what are YOU going to be for Halloween this year?  Do you know?  Or are you still debating?

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  1. Great costumes!
    This year we’ll have a witch, a ballerina and this wolf:
    As for me, I have a pair of crazy pink eyelashes, and that’s it so far 🙂

  2. Hi Oopsey Daisy,
    I was looking for a good costume to use when I take my toddler trick or treating. He also might be Buzz Lightyear and I wanted to stick with the theme. So thanks so much for sharing your idea. Can you give the measurements of the eyes, ears, nose, and mouth cutouts or share a template? Or did you just eyeball it? I guess since its the Potatoe Heads, it doesn’t have to be precise. I may just attach them with velcro so that I can adjust as needed. Thanks again and I hope you and your family have a safe and fun Halloween.

  3. Very cute! I love the family themed costumes 🙂

  4. One year I would love to do Toy Story and this would be perfect! Thanks for sharing!

  5. Hi 🙂
    I am new to your blog and am so excited about Mommy School!! I have been trying for over an hour to download “H is for Halloween” and ended up installing 4shared, but am still not able to download the packet. Before I drive myself crazy, I was wondering if there is some chance it is no longer available? Thank you for all of your help and for all of the time you must put into getting all of this fun stuff together to share!

  6. Thank you so much for your quick response! I was able to download the packet with no problem. It was “operator error”!

  7. We did super easy, homemade Star Wars costumes this year. Both were done for less than $5!

  8. Love it. My daughter is going to be Jesse, so this will be a fun way for my husband and I to be Mr. and Mrs. Potato head. I just have one question. Did you use the same sizing for you and your husband’s costumes?

  9. What a cute costume! I think I’m going to borrow this idea for my daughter. She is still too little to have a preference but i think this is the last time I’ll get to choose her costume for her.
    Thanks for the great instructions!

  10. Thank you so much for the GREAT idea! I made my husband and I one so that we could be a Toy Story family this year…Thanks for the inspiration:
    Thanks again!

  11. The costume turned out great – even though I didn’t make it big enough to do the elastic at the bottom. But I think it worked. Thanks again!


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