Mr & Mrs Potato Head Costumes

Easy to Make Mr & Mrs Potato Head Costumes

These Mr and Mrs Potato Head Costumes were super simple and only cost me $8.97 (for the tan felt).  All other items I had on hand.  Even so, the only other must haves are elastic, hot glue gun/sticks and felt sheets for facial features.
Want to make a set? Let’s get started!
I purchased three yards of tan felt, 72″ wide.
For my husband, who is 6’4″ I measured from his shoulder to mid calf and then added 2″ for a total of 52″.  My final measurement came in at 45″.

DIY Potato Head Costumes

Fold the felt in half and mark the length you need (52″ for hubby).  
Cut straight across.  You now have a 52″ x 72″ piece of felt.
Now that you have the felt cut to size we need to shape it.
To figure out how wide to make it measure edge of shoulder to edge of other shoulder.

DIY Potato Head Costumes

  Fold the felt in half again and mark the center.  Next mark on either side for your measurement – example: My husbands measurement was 20″ so I marked 10″ from the fold.   
The above picture shows the measurement when the fabric is unfolded.

DIY Potato Head Costumes

Keeping the fabric folded in half you are going to cut a semi-potato shape, starting from the 10″ mark.  I slowly angled out until I got to the spot where I wanted my widest point (around a persons bottom – so 24″ for my hubby) and then I rounded it off and down and in until I got to the bottom.  See picture above for shape – left is how I cut it folded and right shows it unfolded.
You should now have the front and back pieces of the potato cut.
ARM HOLE OPTION 1 works good with EARS OPTION 1 and ARM HOLE OPTION 2 is for if you aren’t adding ears or are using EARS OPTION 2.  I tried to explain this as best I could so let me know if you are confused!
Hold the cut fabric up to the persons body and mark where you will want your arm holes and head.

DIY Potato Head Costumes

I folded some pink felt in half and then free cut the ears, but if you aren’t comfortable doing so, then draw up a template on paper first. Pin your ears about an inch below your arm hole – making sure they are pointing in and are sandwiched between the two tan pieces of felt.  
I didn’t want, um… headlights so I put the ears BELOW my arms so that the face was further down.  If you are OK with eye boobies, skip this step,  and use ARM OPTION 1 and EAR OPTION 2 below.

DIY Potato Head Costumes

Now you are ready to sew. Starting at the edge of your neck hole sew across the shoulder and down to the top of your arm hole and back stitch.
Start again at the bottom of the arm hole and go all the way down.
Now do again for the other side.

DIY Potato Head Costumes

 Sew from the neckline all the way to the bottom on one side and then the other.  Have the person try the costume on and mark where the arm holes should go.  Cut a small section out and then do a small stitch above and below so that the seam doesn’t unravel.
Ear option 2 comes later.

DIY Potato Head Costumes

I then folded the bottom up an inch  all the way around to create a casing for the elastic.
Starting on a side seam, sew the casing, leaving a 3″ gap to insert the elastic.

DIY Potato Head Costumes

Using a safety pin, thread the elastic through the casing.
Using a zig zag stitch sew the two ends of the elastic together and sew shut your gap.
If you want to finish off the neck and arm holes just fold the fabric in a half inch and either sew or hot glue in place.

DIY Potato Head Costumes

I also chose to round off the shoulders at this point.
Flip right side out and you have your base is done!

DIY Potato Head Costumes

Next step is to add facial features.  I drew up all of my facial features onto paper and arranged it on the potato – this helped me size everything correctly.  

DIY Mrs Potato Head Costumes
DIY Mr Potato Head Costume

Once I was happy I traced them onto sheets of felt and cut them out.  I made my husband put on his potato and then hot glued everything into place.  I did consider gluing them to velcro so that the pieces could be arranged which I think would be hilarious, but since we will be wearing these at an amusement park I didn’t want to chance loosing anything.
 Did you decide you wanted ears after all and don’t mind them at arm level?  Cut them out and then glue the ears to the front inside of the your arm hole. 
Want to add a bow for Mrs. Potato head?

DIY Potato Head Costumes

 Take a small sheet of craft felt and fold it in half.
Use a pipe cleaner to wrap around the middle creating a bow shape and then secure to a headband with the pipe cleaner.

DIY Potato Head Costumes

Cut a small piece of felt and wrap it around the bow and pipe cleaner and hot glue in place.

DIY Mr Potato Head Costume
DIY Mrs Potato Head Costume

 We wore these babies to the Halloween Party at Disney World and received so many compliments!

Potato Head Couples Halloween CostumesDid you see my daughters Little Mermaid Costume above? I have a tutorial for that as well!

Here are a few more DIY Halloween Costumes:

Simple Frozen Elsa Inspired Dress with Tulle Train

FROZEN Elsa Inspired Dress

Learn how to easily piece together a fun and colorful Tween Monster Costume!

Tween Monster Costume

Quick and easy tutorial for both Daddy and Peppa Pig Costumes! Only requires basic sewing skills!

Peppa and Daddy Pig Costumes



  1. says

    I was really inspired by your post, headed out to Joann’s, and bought all the supplies…but I am stuck (uggg). I am not a sewer. I need some help!!! I have the felt cut from the shoulder mark, slowly angled out (as shown in your third picture). This is where I am lost…Is this the front of the potato and I need another piece for the back or do I somehow fold it so that it makes the whole potato?

  2. Anonymous says

    I’m pretty sure you need two pieces. One for the front and one for the back.

    I’m going to the fabric store to night to pick up supplies :) Super cute costume – thanks for sharing!

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