Toy Story is a gift for anyone who likes to make costumes, because the characters are toys: flat colours, big shapes and a few graphic details that translate straight into felt, foam and cardboard. Below you'll find the main cast, the side characters, the humans and a couple of group ideas, with full outfits from hat to shoes. Many start from a sweatsuit or thrifted clothes and a few craft supplies; a few are worth a wig or a structured piece. What makes each one read is getting the character's signature colours right and keeping the build light enough to move in all evening, so I've noted where a piece tends to fail and how I'd make it.
Felt, Foam or Cardboard for Each Toy
Most of these costumes are a base of plain clothes plus panels, ears, tails and props. The material you choose for those extras decides whether they're still attached at the end of the night.
- Felt for faces, bellies, scales and patches. It doesn't fray, so you can cut and stitch it without hemming. Glued felt peels off stretchy sweatshirts and polyester, so I stitch it on with a few running stitches or use a fabric glue made for flexible fabric.
- EVA foam for anything that should hold a curve, like Buzz's chest or Zurg's shoulders. It shapes with gentle heat and doesn't crease. Thin craft foam is fine for flat details such as letters and maple leaves, but it won't hold a shape.
- Cardboard for big, rigid frames like the Etch A Sketch, Lenny and RC. It's light and free, but it softens in rain and bends at the folds, so seal it with a coat of acrylic paint or clear varnish and reinforce corners with tape inside.
Hot glue is quick, but it goes brittle in cold air and lets go of fabric that stretches. I keep it for foam to foam and card to card, and sew or use fabric glue wherever a piece meets the clothes.
1. Woody Cowboy Costume
Woody is mostly shopping, with a little sewing. You need a yellow plaid shirt, straight blue jeans, a black-and-white cow-print vest, a red bandana, a brown belt with an oval buckle and a light cowboy hat. Cow-print fleece is the easiest vest fabric because it doesn't fray, so you can cut the armholes and leave the edges raw. Swap the holster's toy gun for an empty yarn holster. Brown boots or comfortable ankle boots, natural hair or a short brown wig, rosy cheeks and a few freckles finish him. The sheriff badge and a pull-string ring stitched to the back of the shirt are the details fans look for, and a removable 'Andy' written on one boot sole is the bonus.
2. Buzz Lightyear Space Ranger Costume
Buzz starts with a white long-sleeve top and white pants or leggings, then a chest panel that carries the green, purple, red and blue control details. I make that panel from thin EVA foam rather than cardboard, because foam bends round the chest and survives being sat in, while card creases at the first hug. A purple collar and a soft purple hood that leaves the face open come next, with foam wrist cuffs and wings on elastic straps. Make the wings detachable; they catch in doorways and car seats, and you'll want them off at some point. White sneakers or light boots and clean makeup with defined brows finish the space ranger.
3. Jessie Cowgirl Costume
Jessie needs a white western shirt with yellow shoulder yokes, red trim and cow-print cuffs, plus jeans with cow-print chaps-style panels on the lower legs. Felt or fleece cow print can be stitched on with a wide zigzag; iron-on adhesive tends to peel on denim after a night of kneeling and climbing. Add a wide brown belt, a gold buckle, a red cowgirl hat and brown boots. The long red braid tied with a yellow bow is her biggest marker, so if your own hair won't do it, a braided red wig is worth the money. Warm blush, freckles and a sheriff badge, plus a pull-string on the back, round it out. It suits any age, which makes her a natural for family groups.
4. Classic Bo Peep Costume
The original Bo Peep is all soft storybook shape, and the volume is the hard part to fake. Start with a pink polka-dot dress, or a pink bodice over a full white skirt, with puff sleeves, lace trim and a big pink bow at the waist. A tulle or net petticoat under the skirt gives that bell shape without weight. White bloomers or fitted shorts underneath, white tights and pink flats keep it practical. Soft blonde curls under a matching bonnet, or a curled wig, rosy cheeks and pink lips suit her. A shepherd's crook cut from painted cardboard is light, but double it up and tape a dowel inside or it bends by the end of the night. A small plush sheep is the sweet finishing prop.
5. Adventure Bo Peep Costume
The later, action-ready Bo Peep is the more comfortable of the two. A pale blue jumpsuit, romper or sleeveless top with cropped pants is the base. Wrap a pink polka-dot panel round the waist as the cape-skirt; I'd attach it with hook-and-loop tape so it can come off quickly. Soft wrist wraps, a pink hair bow, a wide blue sash and flat black boots with grippy soles finish the body. Blonde hair goes in a practical ponytail with a few curls left loose at the face, with rosy cheeks and pink lips. A blue staff made from a foam pool noodle or rolled card is light enough to carry for hours. This is the Bo Peep I'd pick for anyone who wants to move freely.
6. Forky Costume
Forky is the easiest build on this list, and one of the most fun to make. An all-white sweatshirt and pants are the spork body. Felt googly eyes in two slightly different sizes, a red brow and a blue felt or craft-foam smile give the face across the chest. Glue on felt with a fabric glue, not hot glue; hot glue goes stiff and peels off a stretchy sweatshirt as soon as it's pulled on. A wide white foam headpiece extends the spork shape without covering the face. Red fabric round the wrists stands in for pipe-cleaner arms, and brown shoes suggest the craft-stick feet. Tuck the hair under the headpiece and carry a small labelled paper cup.
7. Little Green Alien Costume
The aliens are bright, comfortable and easy to sew for adults or kids. A royal blue jumpsuit or sweat set is the base, with a purple collar and a planet emblem on the chest. The hood or beanie carries three big felt eyes and a single antenna on top. For the antenna, I use a pipe cleaner or a flexible wire inside a felt tube with a felt ball on the end, because a stiff stick snaps or pokes someone. If you paint the face green, use skin-safe face paint and patch-test it on the inside of your wrist first; green gloves with a natural face are an easier option. Pointed foam ears and a small claw-machine box or pizza bag finish it.
8. Rex Dinosaur Costume
Rex is a green sweatsuit or jumpsuit with a few clever additions. A lighter green felt belly goes on the front, darker green triangle scales run down the back, and a padded tail is sewn to a belt worn under the top so the weight sits on your hips, not your waistband. Stuff the tail with polyester fibrefill rather than anything heavy; a heavy tail drags and pulls trousers down. Add a hood with rounded eyes, small nostrils and soft felt teeth, foam claws on gloves and green shoe covers over sneakers. Face paint is optional. A toy game controller or a cardboard dinosaur manual nods to his nervous, game-loving side.
9. Hamm Piggy Bank Costume
Hamm needs roundness, so start with a roomy pink sweatshirt and pink joggers and add a circular belly panel. I lightly stuff the belly with a thin layer of batting so it looks like a piggy bank, not a flat patch. The coin slot goes across the upper back, made from foam or card and glued firmly, since it's the one detail people will check. A pink beanie with felt ears makes the head, and a soft snout can sit over the nose or on the hat. If you prefer a bare face, draw two nostril dots with pink eyeliner. Add a curly felt tail at the waistband, pink gloves and sneakers or shoe covers, and carry a few oversized cardboard coins.
10. Slinky Dog Costume
Slinky Dog is clever as a solo costume and even better split between two people. Wear a brown long-sleeve top, darker brown pants and matching shoes, with a tan belly panel, floppy ears and a soft tail. The spring is the tricky bit: a silver dryer-vent-style tube or a ring of silver fabric strips round the waist reads well, but keep it short and light, or it bounces into people's legs. A brown cap can carry the cartoon eyes and raised brows, with a brown nose drawn in makeup. Mittens with soft paw details finish him. For a pair, one person takes the head half and one the tail, and you link with a short silver tube.
11. Mr. Potato Head Costume
Mr. Potato Head is a rounded brown tunic, T-shirt dress or foam panel with soft edges, covered in removable felt features: eyes, ears, brows, a red nose, white arms and a big black moustache. I put a small square of hook-and-loop tape behind each feature, so you can swap them around during the night, which is half the fun. Pair the tunic with black leggings and white gloves, and wear bright blue shoe covers over sneakers for his blue feet. A small black bowler hat finishes him. Keep makeup neutral, because the felt face does the expressions, and carry a drawstring bag of spare features for people to rearrange.
12. Mrs. Potato Head Costume
Mrs. Potato Head uses the same rounded brown tunic, with softer accessories: big felt eyes with lashes, pink ears, a red nose, pink lips and white arms. Black leggings or straight pants underneath, and red or pink shoe covers over flat sneakers. Her small cream hat with a yellow flower is the signature piece, and white gloves make the hands pop. A short black wig with curled ends or your own dark hair under the hat both work. If you're making a pair of potatoes, build both tunics from the same brown fabric so they look like a set; two slightly different browns side by side show up in every photo. Carry spare face pieces in a bright handbag.
13. Toy Story Barbie Costume
For the workout-era Barbie, an electric blue jumpsuit, unitard or matching activewear set is the base. A wide pink belt, bright pink leg warmers, striped wristbands and white sneakers carry the exercise look. Leg warmers are simple to sew from a tube of rib knit if you can't find pink ones. Go big on the high blonde ponytail, or clip in a long ponytail wig. Pink blush, glossy lips and blue eyeshadow suit the polished, playful face, with small gold hoops and a gym bag. If a unitard feels too fitted, layer blue bike shorts over leggings with a long-sleeve athletic top; it reads just as clearly and is much more forgiving.
14. Toy Story Ken Costume
Ken is retro holiday wear plus very deliberate hair. A pale blue short-sleeve shirt, matching tailored shorts and a light blue neck scarf form the base, with a leopard-print belt, loafers and tall pastel socks for the toy-box exaggeration. The blond wig with a smooth, voluminous side part is the most recognisable detail, and synthetic wigs hold that shape well with a little hairspray made for wigs. Light bronzer, groomed brows and a big smile beat theatrical face paint. Carry oversized sunglasses or a plastic comb. On a cold night, pale blue or skin-tone leggings under the shorts save you. He's fine solo and makes an obvious pair with the blue Barbie.
15. Duke Caboom Stunt Costume
Duke Caboom starts with a fitted white jumpsuit or white jacket and pants. Red maple-leaf shapes, red side stripes, a wide belt and a white cape with red lining make him a stuntman. I'd cut the maple leaves from red felt and stitch them on, since they're on the chest and arms where glue gets flexed loose. Tall white boots or shoe covers over sneakers, a thick swept-back dark wig and a horseshoe moustache in face-safe makeup finish him. Carry a light motorcycle helmet under your arm rather than wearing it all night; it's hot, it muffles you and it narrows your view. Red wrist cuffs and a small cardboard stunt-ramp sign are a fun final touch.
16. Gabby Gabby Doll Costume
Gabby Gabby is a vintage doll, so the dress should look a little old-fashioned. A yellow patterned dress with puff sleeves, a white collar and a full knee-length skirt is the base, with white ankle socks and black Mary Janes. A lace petticoat adds volume, and fitted shorts underneath keep it practical. Red hair goes in two neat braids with yellow bows, or wear a braided auburn wig. For the porcelain look, round rosy cheeks, drawn freckles, soft red lips and defined lower lashes do it; keep it gentle, as she tips into creepy fast if the makeup gets heavy. A small storybook or toy microphone is the prop. Iron the collar flat, because a limp collar undoes the doll effect.
17. Benson Dummy Costume
Benson can look theatrical without being frightening. A black tuxedo jacket, white shirt, black bow tie, fitted black pants, polished black shoes and white gloves make the formal base. Slick dark hair back with gel, or wear a neat black wig. Pale foundation, round pink cheeks, sharp brows and two faint lines from the corners of the mouth suggest a ventriloquist dummy. Draw those lines with a soft brown eyeliner pencil and set them with powder; liquid liner cracks as you talk and smile. Keep the expression friendly and skip cracked or distressed effects. A red handkerchief in the pocket adds colour, with a small stage sign or a light suitcase for your essentials.
18. Ducky Costume
Ducky is cosy and warm, which is why I'd steer anyone trick-or-treating on a cold night towards him. A fuzzy yellow hoodie, yellow joggers and matching sneakers or shoe covers make the base, with a pale orange belly and small felt wings along the sleeves. The hood takes round eyes, a soft orange beak and a tuft of yellow fabric on top. If you'd rather keep the hood plain, golden eyeshadow, rosy cheeks and an orange beak shape painted round the lips work. Orange tights or socks between pants and shoes make bird legs. Fuzzy fleece sheds while you cut it, so cut it outside or over a sheet. A carnival prize tag finishes him.
19. Bunny Costume
Bunny is Ducky's natural partner. A plush blue hoodie and loose matching pants, a lighter blue belly, purple inner ears and a small violet nose set him up. Long padded ears can be stiffened with a pipe cleaner or millinery wire sewn into the edge, but keep them light, or the hood slides back off the head. A strip of hook-and-loop tape inside the hood brim stops that. Blue sneakers or furry shoe covers, soft blue eyeshadow, pink cheeks and a purple nose dot finish the face, with white gloves and felt paw pads. Carry a carnival prize ribbon or a ticket-shaped bag, and make the pair together so the fabrics match.
20. Lotso Bear Costume
Lotso is a strawberry-pink teddy bear with cream accents. A plush pink hoodie, matching joggers and pink sneakers or paw covers are the base. Add a cream belly, rounded ears and a short tail, and put big eyes, dark brows and a deep pink nose on the hood. Rosy makeup, berry lips and light pink eyeshadow tie the face to the suit. A strawberry bag or removable strawberry patch nods to his scent. I'd keep the expression cheerful rather than villainous, unless you're going as the scheming version on purpose. Pink fleece gets very warm indoors, so for a warmer party, a pink tee, shorts and light felt pieces carry the same idea.
21. Emperor Zurg Costume
Zurg is a construction project, mostly in foam. A structured purple tunic over black pants and a black long-sleeve shirt is the body, with a red-lined cape, a silver chest panel and geometric red details cut from craft foam. The big shoulders are what make him read; I build them from EVA foam shaped with a heat gun, which holds a curve where craft foam just goes floppy. Black gloves and sturdy boots, and a purple helmet or open-face hood with silver side pieces and yellow eyes above your own, finish the head. Purple and gray makeup at the temples adds depth. Skip the blaster and carry a foam control panel instead.
22. Stinky Pete Prospector Costume
Stinky Pete is an old-time prospector with a toy's proportions. A red plaid shirt, faded blue overalls, a brown vest and work boots form the base, plus a wide-brim brown hat, a red neckerchief and gray gloves. A short gray wig and a full white beard give the face. Fit the beard so it clears your mouth and nose comfortably, because you'll want to eat and talk. Warm, weathered makeup with rosy cheeks works better than dark grime. A foam pick-shaped walking prop is fine only if the venue allows costume tools; otherwise a gold pan or a cardboard gem sack carries the theme. Buy the clothes a size big for that slightly oversized collectible-toy look.
23. Wheezy Penguin Costume
Wheezy is simple and soft, and suits almost any age. A black hoodie and black pants, a large white oval belly, short black fabric wings along the sleeves and a small tail make the penguin. Orange socks with black sneakers, or orange felt shoe covers, give the feet. The hood takes round white eyes and a soft orange beak, and the red bow tie under the chin is the detail that turns a penguin into Wheezy specifically. Keep makeup light. A silver toy microphone, or one made from a cardboard tube and a foil-covered ball, plays up his singer side. White felt on black fleece looks crisp, but it shows lint, so give it a quick roll before you go.
24. Green Army Soldier Costume
The Green Army man only works when every visible piece is the same matte green, so match colours in daylight before you commit. A green button-down, cargo pants, a utility belt, gloves and lace-up boots are the base. Paint cheap accessories or use fabric covers so the shades match. Add a green helmet and solid toy-green face paint rather than realistic camouflage markings. Carry binoculars, a folded map or a cardboard radio instead of a weapon. The flat oval base strapped under your shoes is great for photos, but take it off to walk, because you can't use stairs in it. Freeze in a stiff action pose for every picture.
25. Bullseye Horse Costume
Bullseye is a comfortable one-person horse. A brown hoodie and matching pants are the base, with a lighter tan belly and muzzle. The dark brown mane runs down the hood and upper back; I cut it from a double layer of felt snipped into fringe, which stands up better than a single layer. Upright ears, big cartoon eyes and a soft black nose go on the hood, with a long brown fabric tail and black felt hoof covers over brown sneakers. Bronzer and a small black nose dot work if your face shows. A removable felt saddle in red and brown is the last piece. He's lovely alongside Woody or Jessie.
26. Big Baby Doll Costume
Big Baby stays fun when you focus on the oversized nursery details and leave the creepy side out. A pale yellow footed pajama-style jumpsuit or a yellow romper over a cream long-sleeve top and leggings is the base, with white socks and soft beige shoes. A bald cap is the faithful option, but it's hard to blend at the edges, so a smooth beige beanie is the forgiving choice. Round pink cheeks, freckles and wide doll lashes give the face; skip cracked or distressed effects. Carry an oversized foam bottle, a fabric rattle or a patchwork blanket, and add a big silver craft-foam safety pin on the front.
27. Etch A Sketch Costume
The Etch A Sketch is a wearable frame. Cut a red rectangle from foam board with a large opening in the middle, so a gray shirt or dress shows through as the screen. Add two oversized white knobs near the lower corners and the label across the top in yellow craft foam. Red pants or leggings and white sneakers keep the palette tidy. Draw a picture on the gray fabric with fabric chalk, which brushes off so you can redraw it later. Shoulder straps behind the frame keep your hands free. Foam board dents and softens in rain, so if you're out trick-or-treating, I'd seal it with a coat of clear acrylic first.
28. Lenny Binoculars Costume
Lenny is a less obvious choice that people enjoy spotting. A royal blue sweatshirt and pants with black sneakers are the base. Two blue cardboard tubes, joined across the chest with wide straps, form the binoculars; mailing tubes or large paper-towel tubes covered in blue paper are light and already round. Big eyes go on the front of the tubes, and they must sit well below your own sightline. A soft black cord at the neckline makes the strap. Tuck hair under a blue cap or tie it back, and add bright blue eyeshadow and rosy cheeks. A lookout map or scavenger-hunt list suits his watchful character.
29. RC Car Costume
RC turns a toy car into a cardboard ride-in costume. A green long-sleeve top, dark pants and green or black sneakers are the base. Build a light cardboard car body that hangs from shoulder straps at the waist, then paint it lime green with blue, yellow and red racing details. Foam wheels on the sides and a small spoiler at the back finish the car. Keep it narrow; a car body wider than your shoulders hits doorframes and other people, and you'll be turning sideways all night. A green helmet or cap with checkerboard accents and painted cheek stripes suits it, and a big handmade remote is a great job for a partner.
30. Pizza Planet Delivery Driver Costume
The Pizza Planet driver is a closet costume with one clever detail: the logo. A red cap, a white short-sleeve polo, dark jeans and red-and-white sneakers are the base. Put a planet-and-pizza-style logo on the cap and shirt with printable iron-on transfer paper or layered felt; transfer paper looks sharper, while felt is easier to remove afterwards. A red apron makes the restaurant uniform more obvious. Tuck your hair under the hat and keep makeup natural. An empty pizza box decorated with space graphics or a small insulated delivery bag is the prop, and a homemade name tag adds personality. It's a good fit for adults who don't want a character suit.
31. Andy Costume
Andy is the subtle option, and it's mostly about one detail. A bright blue tee, relaxed jeans, white crew socks and classic sneakers are the whole outfit. The giveaway is 'Andy' written on the sole of one shoe, so use removable vinyl or masking tape lettered with a marker, and lift your foot in photos. Short hair stays natural, longer hair can go in a low ponytail, and makeup is clean and minimal. A cardboard moving box labelled for toys, or plush versions of a cowboy and a space ranger, finish the story. Add a light zip hoodie for an older Andy. You can wear it to school or work and still be in costume.
32. Sid Costume
Sid's look is rebellious kid, minus anything genuinely disturbing. A black tee with a big white cartoon skull, straight jeans and black canvas sneakers are the base. A short dark wig or a slightly messy crop, smudged gray shadow under the eyes and brushed-up brows give the face. A red cap worn backwards adds colour. If you can't find the skull tee, a white skull cut from felt or printed on transfer paper works on any plain black shirt. Carry a cardboard toolbox of harmless craft pieces, foam blocks and mismatched toy parts. Leave out sharp tools and mutilated toys, which upset small children in a crowd.
33. Bonnie Costume
Bonnie is school-day clothes plus a lot of handmade craft. A purple or blue tee, denim overalls, striped socks and bright sneakers make the base. A backpack covered in felt shapes, crayons and removable paper cutouts carries her artsy side. Brown hair in a loose ponytail, or a natural brown wig, with rosy cheeks and a few freckles is plenty of makeup. The best prop is your own Forky: a clean plastic spork, pipe-cleaner arms, a craft stick and googly eyes. Glue the googly eyes on firmly, since they're a choking risk around small children if they pop off. A paper name tag and a child-safe art box finish it.
34. Woody And Bo Peep Couple Costume
Woody with the adventurous Bo Peep makes a strong couple. One person wears Woody's yellow plaid shirt, cow-print vest, jeans, red bandana, cowboy hat and brown boots, with a brown wig if needed. The other wears a pale blue jumpsuit, the pink polka-dot waist cape, black boots and a big pink bow, with blonde curls or a ponytail. Keep both faces bright and friendly. A sheriff badge, a pull-string on Woody's back, a light shepherd's staff and a plush sheep fill out the story. Matching name labels on both shoe soles are a sweet shared detail, and I'd use the same lettering style on each so they look like they came from one toy box.
35. Toy Story Group Costume
A group costume lets everyone pick a different shape while the theme holds you together. Build the main lineup from Woody, Buzz, Jessie, Bo Peep, an alien, Rex and Forky, then add others as the group grows. Each person needs a complete outfit with the right hat or wig, makeup, prop and comfortable shoes. Matching shoe-sole labels or treat bags with the same cloud print connect everyone visually. Give taller adults the structured builds like Buzz, and let children pick soft costumes like Rex or the alien, which they can sit and run in. Let people choose the characters they love rather than assigning them by gender. Line up shortest to tallest for the group photo.
Tails, Ears and Belly Panels That Stay Put
Rex, Hamm, Bullseye, Slinky and the carnival pair all rely on add-ons, and add-ons are what fall off first. A few habits make them last a whole evening of running and sitting.
- Hang tails from a belt, not from the trousers. Sew the tail to a strip of webbing or an old belt worn under the top, so the weight sits on your hips.
- Stuff lightly. Polyester fibrefill keeps a tail or belly round without weight; anything heavier swings and pulls.
- Stiffen ears from inside. A pipe cleaner or soft wire sewn into the edge of a felt ear lets it stand up and bend back when someone hugs you.
- Use hook-and-loop tape for anything removable. Wings, cape-skirts and Potato Head features come off for car rides and dinner, then go straight back on.
Before the big night, wear the costume around the house for half an hour, sit in a chair, climb some stairs and give someone a hug. Whatever shifts or drops off then will do the same in a crowd, and it's much easier to fix at the kitchen table.
Start With the Colours, Then Add One Detail
Every character here comes down to the same recipe: get the signature colours right, then add the one detail that names the toy, whether that's a coin slot, a pull-string or three felt eyes. Pick a favourite character, or a whole cast for a family or friend group, and build from clothes you already have. Most of these need little real sewing. Keep accessories light, make sure everyone can see clearly, wear comfortable shoes and add layers you can shed. A classic cowboy, a cheerful alien or a handmade Forky will all read well, as long as the costume suits the person wearing it.
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