Mr Potato Head is a costume I like making because the character is basically a brown shape with a face stuck on it, and that's an easy thing to sew, glue or tape together. The parts people recognise are always the same: a brown body, white arms and hands, big features, blue shoes and a black bowler hat. Below are thirty versions built on that idea, for adults, couples, kids, babies, families, big groups and even a dog. Some are proper sewing projects, some are no-sew felt and glue, and some start from a T-shirt or hoodie you already own. I've noted the construction detail that makes each one work and the places where it usually goes wrong.
Drafting a Potato Tunic That Hangs Right
Most of the versions below start from the same simple tunic, so it's worth getting the shape right once. You don't need a pattern. A sheet of wrapping paper or newspaper taped together is enough to draft it.
- Measure across your shoulders and around the widest part of your body, then add about a hand's width of ease so the tunic hangs loose.
- Draw a tall egg on the paper: narrower at the shoulders, widest just below the waist, and rounded at the bottom. Potatoes are lumpy, so a slightly uneven edge looks more right than a perfect oval.
- Mark a wide, shallow neckline and armholes deep enough for a sweatshirt underneath.
- Cut the front and back from brown felt or fleece using the same paper piece, then join them only at the shoulders and the upper part of the sides.
- Try it on before you add any features. Mark where your eyes and mouth should go while you're wearing it, because the face always sits higher on the body than you expect.
Felt doesn't fray, so the edges can stay raw, but it also doesn't stretch. If you want to sit in a car or a classroom chair, leave the sides open from the hip down or add ribbon ties.
1. Classic Mr Potato Head Costume
For the classic version, I cut a rounded brown felt tunic that ends around mid-thigh, front and back the same shape, with enough width at the hips that you can still sit down. Felt doesn't fray, so the edges can stay raw. The face goes on in felt or thin craft foam: big white eyes, black brows, a pink nose, red ears, a smile and a black mustache. Cut the eyes larger than you think; at arm's length they shrink. The black bowler hat is what turns a brown sack into the toy, so don't skip it. A white long-sleeved shirt underneath gives you the plastic arms, and white gloves, blue shoe covers and black trousers finish the outfit. Tuck your hair under the hat, and carry a spare mouth or mustache that people can swap on during the party.
2. DIY Felt Mr Potato Head Costume
This is the felt version I'd make for school and trick-or-treating, because it weighs almost nothing. Cut a loose A-line tunic with shoulder seams and wide armholes; if you're sewing, a straight stitch about a centimetre from the edge is all felt needs. Then layer the features across the front: wide eyes, curved brows, a red nose, pink ears, a mustache and white teeth. A few dots of black fabric paint make potato dimples without adding bulk. Underneath, a white sweatshirt and black joggers keep you warm. A black felt bowler, white cotton gloves and blue felt shoe covers over trainers finish it. One small upgrade I always add is a brown pouch stitched to the back to hold spare features, so they don't end up in a pocket and get crushed.
3. No Sew Mr Potato Head Costume
No needle? You can still make a decent one. Cut two matching potato shapes from brown felt and join them at the shoulders with fabric glue or wide hook-and-loop strips, leaving the sides partly open with ribbon ties so the fit adjusts. Fabric glue needs a full night to cure on felt, so don't build it on Halloween morning. Glue big craft-foam features to the front and keep them flat, with the eyes above your waistline so they don't fold when you bend. Wear it over a white long-sleeved tee and black trousers, then add a ready-made black derby hat, white gloves and blue trainers. A brown drawstring bag decorated like a potato sack makes a good treat bag.
4. Last Minute Mr Potato Head T Shirt Costume
The T-shirt version is the one I point people to when they have an evening, not a weekend. Buy the brown shirt a few sizes up so the whole face fits on the front without crowding. Adhesive-backed felt is the fastest way to cut the features, but the sticky backing lets go on a stretchy knit once the shirt moves, so add a few stitches at each corner if you can. A fitted white shirt underneath gives you the white arms. Black jeans or leggings, bright blue trainers, white gloves and a party-shop bowler hat are all you need beyond that. Since the hat covers your hair, there's nothing to style. For a prop, glue a spare felt mouth to a craft stick and use it like a photo-booth sign.
5. Cardboard Mr Potato Head Costume
Cardboard gives you a stiff, toy-like potato that felt never quite manages. Flatten a big box and cut two rounded panels, paint them mid-brown with darker speckles, and join them with wide fabric shoulder straps; narrow straps cut into your shoulders within an hour. Painted card or foam works for the eyes, pink ears, orange nose, red mouth and mustache. If the shell comes up around your head, cut a viewing window between the brows and cover it with dark mesh. The weak point is the edges: card scrapes arms and catches on doorframes, so round every corner and run tape along each edge. A white sweatshirt, black trousers, cushioned trainers with blue covers and a light foam hat on top finish it. Keep it out of the rain, because wet cardboard sags.
6. Interchangeable Mr Potato Head Costume
The mix-and-match version is the most fun at a party, because guests end up playing with you. Start with a brown felt tunic padded with a thin layer of batting so the front holds its shape, then sew wide hook-and-loop patches across the face area. Sew the soft, fuzzy loop side onto the tunic and put the scratchy hook side on the foam features; that way the tunic won't snag your sweater or pick up fluff. Make several sets: surprised eyes, a smile, different noses and mustaches, a few brows. Underneath, a white long-sleeved shirt, black trousers, white gloves and blue sneaker covers. Put elastic on the bowler hat, because people will knock it while swapping parts. A roomy pocket on the back keeps the spares.
7. Inflatable Look Mr Potato Head Costume
If you want the puffed-up look of an inflatable suit without being sealed inside one, this is the way to do it. Cut a roomy potato tunic from brown fleece and stuff the front and back lightly with batting. I stitch a few vertical channels through both layers so the stuffing can't slump to the bottom by the end of the night. Raised foam features give it depth: round eyes, a big nose, red ears, a smile and a plush mustache. Wear a white thermal top, black leggings, white gloves and blue slip-on shoe covers. A padded bowler balances the wide body. Long hair goes in a low bun under the hat. Make the bottom opening and the armholes generous, because stuffed fleece gets warm indoors.
8. Mr Potato Head Hoodie Costume
A brown hoodie makes a warm base, which I'd pick for a cold night outside. Put the felt eyes, nose, ears, brows, mouth and mustache on the front of an oversized hoodie, and position the ears right at the side seams so they stick out a little and give the head some width. Hoodie fleece is stretchy, so stitch the features on or use removable hook-and-loop; glue tends to crack when the fabric stretches. A small black bowler can sit over the hood or be stitched straight onto it. Black joggers, white gloves and blue high-tops finish it. Braids or a low tie keep hair under the hood. Keep a spare felt mouth in the front pocket to change the expression for photos.
9. Mr Potato Head Dress Costume
The dress version keeps the funny proportions but looks tidier than a tunic. A brown sleeveless shift or a simple felt A-line that ends above the knee is the base, and the face goes across the front: big felt eyes, black brows, a red nose, pink ears, smiling lips and a curved mustache. Felt is stiff, so if you're sewing the dress yourself, add a few darts or cut it a little wider at the hem so it doesn't stand out like a lampshade. A fitted white turtleneck and white gloves give you the toy arms. Black tights and bright blue ankle boots finish the outfit. A mini bowler on a headband lets you keep your hair styled in a bun or soft waves. Carry a small brown bag decorated with removable features.
10. Mr Potato Head Overalls Costume
Overalls are comfortable for a long night, and the bib is a ready-made flat panel for the face. Wear brown overalls or a brown bib apron over a white long-sleeved shirt, and arrange the features on the bib: white eyes, black brows, pink ears, an orange nose, a red smile and a mustache. If it looks too flat, sew a rounded brown fabric panel behind the bib to fill out the potato shape. White gloves, black socks and bright blue trainers finish the outfit, with a black bowler on top. Hair can go under the hat or in a low ponytail. A small toy basket of spare foam eyes and mouths is a good prop, and friends always want to have a go.
11. Vintage Mr Potato Head Costume
For a vintage version, I knock the colours back a step. Tan canvas or brown felt makes the body, then cream eyes, brick-red lips, pale pink ears and a charcoal mustache instead of the bright plastic colours. To get the worn-toy look, brush on some diluted brown fabric paint and wipe most of it off with a rag; it settles into the texture and looks aged. Canvas frays, so hem it or seal the cut edge with fray-stop. Wear it over a crisp white shirt, straight black trousers and white gloves, with a slightly oversized bowler and navy shoe covers over loafers or trainers. A small cardboard sign shaped like an old toy box is enough of a prop. It's a good fit for a nostalgia-themed party.
12. Glam Mr Potato Head Costume
Glitter turns the potato into a party look. A fitted brown tunic or simple shift with a scattering of bronze sequins is the base, and the features are cut from glitter craft foam: bright eyes, arched brows, glossy red lips, pink ears and a neat mustache. Glitter foam sheds less than loose glitter, but its back is slick, so rough it up with sandpaper before you glue it or it will pop off. Wear a white fitted top, white gloves with rhinestone cuffs, and blue ankle boots or sparkly blue trainers. A small black glitter bowler on a headband replaces the full hat. Smooth waves or a sleek low ponytail and glowy makeup suit it. Carry a compact mirror decorated like a spare feature.
13. Scary Mr Potato Head Costume
The spooky version keeps it silly rather than gory. Use a dark brown felt tunic and give it mismatched foam eyes, sharply angled brows, a crooked purple nose, pointed ears and a wavy mustache. Grey and charcoal fabric paint, dry-brushed on, makes the body look weathered. Dry-brushing means almost no paint on the brush, wiped off on a paper towel first, so the colour catches only the raised texture of the felt. Wear it over a black long-sleeved shirt and black trousers with white gloves and deep blue boots. A bent bowler gives it a haunted look. Leave your hair messy under the hat and add grey eyeshadow with exaggerated brows. A couple of reversible felt faces, a grin on one side and a shocked mouth on the other, make good props.
14. Rainbow Mr Potato Head Costume
The rainbow version keeps the brown body but makes every feature a different colour: blue eyes, purple brows, pink ears, an orange nose, a red mouth and a green mustache. That only works if the body stays plain brown; once the body is colourful too, it stops looking like a potato. Rainbow ribbon around the armholes and hem is enough trim. A white long-sleeved shirt, white gloves, black leggings and mismatched bright trainers sit underneath. Wrap the bowler in a striped band. You can wear a multicoloured wig under the hat if you want more colour, and add a few bright makeup accents near the eyes. A rainbow drawstring bag holds spare foam features for photo swaps.
15. Monochrome Mr Potato Head Costume
The monochrome version looks like the toy has walked out of an old black-and-white film. Cut the body from mid-grey felt, then make white eyes, pale grey ears, a charcoal nose, black brows, a black mustache and a white smile. Grey features on grey felt disappear from a distance, so outline each one with black fabric paint; that outline is what keeps it readable. Wear a white button-down, black trousers, white gloves and black-and-white trainers, with a matte black bowler held on with hidden elastic. Slick your hair back or tuck it under the hat. Grey-toned makeup with soft charcoal eyeshadow finishes the old-film effect. A small black-and-white sign or a removable expression panel is the prop.
16. Child Mr Potato Head Costume
For a child, I keep it soft, light and short. A loose brown fleece tunic that stops above the knees and has big armholes is the base, so they can run and climb. The features should be flat felt, not thick foam, and stitched rather than glued, because kids pick at anything that lifts. Layer it over a white sweatshirt and comfy black joggers, then add white mittens, blue trainers and a soft felt bowler on gentle elastic. Skip face paint; rosy cheeks are plenty. A small brown treat bag can carry a few spare features. Only use hook-and-loop swap pieces if every piece is large and suits the child's age.
17. Toddler Mr Potato Head Costume
For a toddler, I'd make a short brown poncho with a wide neck opening rather than a tunic, because ponchos go on over the head in one move and don't fight with wriggling arms. Sew the features on securely: large felt eyes, an orange nose, red ears, a smile, black brows and a soft mustache. Leave off anything that dangles or comes off, since toddlers put things in their mouths. Dress them in a white cotton shirt, black leggings or joggers and blue non-slip shoes, and only add mittens if they'll keep them on. A soft black hat with a rounded brim is safer than a stiff costume hat. Skip makeup entirely. Make sure the poncho ends well above the feet so they don't trip, and keep any plush potato prop light.
18. Baby Mr Potato Head Costume
For a baby, a soft brown romper beats any kind of shell, because babies spend most of the night lying down or in a car seat. Sew flat fabric features to the front: wide eyes, round ears, a small orange nose, a happy mouth, brows and a plush mustache. Stitch them all the way around, not just at the corners, so there are no edges for little fingers to pull. A white long-sleeved bodysuit underneath adds warmth, with black leggings, white socks and soft blue booties. A flexible bowler-style cap is enough on top. No face paint or makeup on a baby. For stroller photos, a brown blanket with big toy-like features gets the idea across.
19. Plus Size Mr Potato Head Costume
For a plus-size version, I draft the tunic from your own shoulder, chest and length measurements instead of trusting a one-size pattern, which usually ends up tight across the chest and short at the back. An A-line shape in brown felt drapes well; add side slits and ribbon ties for extra movement. Space the eyes, ears, nose, mouth, brows and mustache across the torso so each piece is clearly visible. Wear a breathable white long-sleeved shirt, stretchy black trousers and supportive blue trainers, plus white gloves and a light bowler. Hair can go in a low bun, braids or natural curls under the hat. A crossbody pouch hidden behind the tunic holds your phone, keys and spare features.
20. Mr And Mrs Potato Head Couple Costume
For a Mr and Mrs pair, I make two matching brown felt tunics from the same pattern and let the faces and accessories tell them apart. He gets the black mustache, red nose, toothy smile, black bowler, white shirt, black trousers, white gloves and blue shoe covers. She gets long lashes, pink lips, a yellow nose, white gloves, red or pink shoes and a small flowered hat. Attach each feature with hook-and-loop so you can swap faces during photos, which always gets a laugh. Hair stays neat under the hats and makeup stays simple and rosy. Matching brown treat bags hold the spare eyes, mouths and noses.
21. Mr Potato Head Best Friend Costume
Two friends can match without looking like a couple. Make two brown tunics from felt, fleece or oversized sweatshirts, and give them different faces: one with blue eyes, a red nose, a mustache and a bowler, the other with green eyes, a purple nose, smiling lips and a bright cap. Both wear white long-sleeved shirts, white gloves, black trousers and contrasting bright trainers. Keep makeup light, maybe with some blush or drawn-on brows. Split a batch of interchangeable foam pieces between two belt pouches so you can borrow from each other through the night. Using the same brown for both tunics is what ties you together, so cut them from one length of fabric if you can.
22. Mr Potato Head Family Costume
A family set is easy because the base changes with age while the idea stays the same. Felt tunics for the adults, ponchos for the kids and a soft romper for the baby all read as potatoes side by side. Give each person a different expression so nobody is a copy. Adults can take the bowler hats and mustaches, and the children can have cheerful mouths, caps, flowers or huge brows. Everyone wears white tops, black bottoms, white gloves or mittens and blue, red or green shoes. Keep makeup to little or none for the kids. I'd cut every family member's brown from the same fabric so the colours match in photos; two browns side by side look like a mistake.
23. Mr Potato Head Group Costume
For a big group, give everyone the same brown tunic and a different mood: happy, surprised, sleepy, silly or confused. The mood comes from the eyes, brows and mouth, so spend your time on those and keep the noses and ears simple. Everyone wears white shirts, black trousers, white gloves and bright trainers. Mix up the headwear with bowlers, caps, flower headbands and visors so the lineup looks varied. Simple makeup can push each mood a little. Give one person a big brown pouch of interchangeable parts, and during photos everyone can trade pieces until you end up with a wall of mixed-up faces. Cut all the tunics from one bolt of felt if you can.
24. Mr Potato Head School Costume
For school, the costume has to survive a whole day of sitting, writing and crafts, so I keep it flat and simple. An oversized brown T-shirt or sleeveless felt tunic with glued-down features is the base: white eyes, black brows, pink ears, a red nose, a smile and a soft mustache. A white long-sleeved shirt and black joggers go underneath, with comfy blue trainers. White cotton gloves come off easily for writing. Pick a light felt hat that won't block the view of the child sitting behind. Hair stays neat under the hat, and rosy cheeks are the only makeup. Instead of loose swap pieces, which get lost by lunch, print a few expressions on a brown folder and carry that as the prop.
25. Office Mr Potato Head Costume
At the office you need to sit at a desk and type all day, so stiff shells and bulky padding are out. Start from a brown sweater dress, a long jumper or an apron-style tunic, and attach slim felt features with removable fabric-safe strips so the jumper goes back to normal afterwards. A white collared shirt with slim black trousers or opaque tights goes underneath. Wear white gloves only for photos and take them off to type. Blue loafers, flats or clean trainers are fine. A small bowler on a headband is easy to take off for meetings. Keep hair polished and makeup low-key. A brown laptop sleeve decorated like the toy's storage hatch is a useful prop, and a few spare features help in a costume contest.
26. Mr Potato Head Pajama Costume
The pyjama version suits a relaxed party or a school spirit day. A roomy brown pyjama set, a hooded onesie or a matching sweatshirt and joggers is the base, with big felt features on the top half and the trousers left plain. Add a red nose, pink ears, friendly eyes, black brows, a curved mustache and a smile. Brushed pyjama fabric pills where glue meets it, so I'd stitch the features or use hook-and-loop. White knit gloves and blue slippers with proper soles finish it, and a soft black sleeping cap shaped like a bowler is the joke. Hair can be loose or tucked into the hood, with just a touch of blush. A brown pillow decorated with spare expressions doubles as a prop.
27. Mr Potato Head Sports Costume
The sporty version swaps the felt tunic for a brown jersey-style top and activewear. Put the eyes, ears, nose, mouth, brows and mustache on in lightweight felt, and add a number on the back rather than a real team logo. Jersey stretches, so stitch the features or use a stretchy fabric glue; standard craft glue cracks as soon as you move. A white performance shirt, black athletic trousers, white gloves and blue running shoes go underneath. Swap the bowler for a black foam visor or a small hat that stays put when you move. A low ponytail and sweat-resistant makeup suit it. A soft foam ball is a fine prop if the event allows. The breathable layers make this a good one for outdoor gatherings.
28. Mr Potato Head Vacation Costume
The holiday potato adds travel details to the classic brown tunic with its eyes, ears, nose, smile, brows and mustache. Layer a bright short-sleeved shirt over the sides of the tunic, or sew a colourful fabric collar around the neckline if you'd rather not wear a second layer. White gloves, black shorts or leggings and comfortable blue trainers go below. Swap the bowler for a wide-brimmed black sun hat and put oversized sunglasses above the costume's eyes, which is the bit that makes people laugh. Hair goes under the hat, with light makeup. A camera-shaped prop and a brown crossbody bag for your things finish it, and a paper map or postcard pinned to the bag adds detail without bulk.
29. Mr Potato Head Pet Costume
A pet costume has to be simple and only worn while you're watching. Start with a lightweight brown pet vest that fits without pressing on the neck, legs or tail. Sew the flat fabric eyes, brows, ears, nose, mouth and mustache on securely, and leave off anything removable, stiff foam, elastic near the face, or anything the pet could chew. Stitch a soft black hat to the vest behind the head instead of putting it on the ears. Leave the face completely uncovered. A comfortable harness and a blue lead finish it; skip shoes unless the pet already wears booties happily. Keep photo sessions short, and take it off at the first sign the animal is unhappy.
30. Mr Potato Head And Toy Group Costume
For a toy-box group, build everyone around one full Mr Potato Head: brown tunic, big eyes, ears, nose, mouth and mustache, white sleeves and gloves, black trousers, blue shoe covers and a bowler. Everyone else dresses as a generic retro toy, in bright jumpsuits, building-block tunics, plush animal outfits or doll-inspired clothes. Building-block tunics are easy to make from two painted card panels with a few circles glued on top. Keep everyone's makeup clean and toy-like, and avoid big props that make it hard to move as a group. The potato carries the spare features, and the others can carry light boxes or giant playroom accessories. Sticking to bright primary colours is what makes the separate costumes look like one toy box in photos.
Glue, Stitches or Hook-and-Loop for the Features
The features are what fall off first, usually halfway through the night. How you fix them depends on the base fabric and on whether you want them to swap.
- Felt on felt: fabric glue holds well once it's fully cured, which takes a night. A few stitches around the edge make it permanent.
- Foam on felt: hot glue grips at first but goes brittle in cold air, so foam eyes often pop off outdoors. Fabric glue or a couple of stitches through the foam last longer.
- Anything on knit: T-shirts, hoodies and pyjamas stretch every time you move, and stiff glue cracks. Stitch the features or use a flexible fabric glue made for stretch fabrics.
- Swappable features: sew the soft loop side of hook-and-loop onto the costume and stick the hook side on the backs of the pieces. Sticky-back strips peel off felt within hours, so sew at least the side on the costume.
Whichever method you use, cut the big pieces like the eyes and mouth from a stiffer material such as craft foam or doubled felt. Thin, floppy features fold over when you move and stop looking like a face.
Brown Felt, a Bowler Hat and a Face That Changes
Every version here comes back to the same short list: a brown base, big features, white arms, blue shoes and something on the head. Once you have those, the material is up to you. Felt is the easiest to sew or glue, fleece and sweatshirts are the warmest, and cardboard gives the stiffest toy shape. Removable features are worth the extra half hour because they turn one costume into a game. Whatever you pick, keep it light, make sure you can see clearly, and leave room to move and sit.
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