Our family did a Toy Story theme for Halloween 2007. Our sons were Woody and Buzz (store-bought costumes, I'm sorry to say) but my husband and I were Mr. Potato Head (me) Zurg (him).
This Mr. Potato Head costume was relatively easy to construct. I bought 2 yards of tan felt for the body. I drew a potato shape, sewing around the edges except for holes for my head, arms and legs. The face pieces were drawn on felt and hot glued on the body.
The hat was made from black poster board that I wrapped around my head. I cut out a circle from the black poster board for the top of the hat as well as a ring for the head band. I just packing taped the pieces together and cut out a slit for my eyes.
The shoes were made from blue foam paper. It took 2 pieces of foam per shoe. I cut an outline on each, measured around my shoes, and packing taped the pieces together. I just slid my foot in through the top of the Potato shoe.
The shirt is simply a white long-sleeved shirt and the gloves are over-sized white puffy gloves.
I first started this Mister Potato Head costume making a wire mold with 2x4 wire fencing. I then sprayed expanding foam (like to insulate around doors and windows) all over the wire. After many coats, I then carved with a saw and sanded until I reached the correct shape. I also put in a trap door in the back to store all the extra parts (like the original).
All the parts were removable and interchangeable. For this I used 2 different size PVC pipes. for the parts I used the same idea with the wire and expanding foam and inserted the PVC into the wet Foam. It took a long time to carve and sand the foam just right, but it was worth it.
Let me know what you think and if you have any questions on how to create your Mr. Potato Head costume.
My son was two and was crazy about his Potato head, so we decided that he would have a Mr. Potato Head costume for Halloween.
I just took brown cotton fabric and made a big sleeve with it and gathered it at the top and bottom and put elastic. I used foam and card board to make the pieces. I also made a fabric flap on the back and ironed on pictures of extra pieces. Just like the real thing!
For his feet I just let him wear his tennis shoes but I covered them with a pair of blue socks. He looked as cute as can be and it was so easy to make.