We made our Coolest Homemade Mr. and Mrs. Potato Head Costumes entirely out of felt. We used about 3 yards each of brown fabric for the body and other scraps we had for the parts.
Most of the parts were stuck on with hot glue. The sides of the poncho-like body and the ears were sewn on but safety pins could work if a no-sew option were needed. The picture doesn’t show it well but we added a little detail to the ears and lips by sewing a line of thread around the outside of the ear and across the mouth line of the lips.
The biggest challenge we encountered was the placement of the ears. On our first attempt we put the ears in the middle of the costume but wearing it was awkward having the ears below the hands (although he IS Mr. Potato Head). In the end we stitched the ears to the front of the arm holes.
We were able to find a cheap Derby hat at a party store and borrowed Mrs. Potato Head’s hat from a lady we know with a large collection.
The one thing we really needed to add would be extra large shoes. We thought about making them out of Paper Mache’ but ran out of time.