Hello, my name is Laura, I’m a senior in high school, and I make crazy costumes for my school’s spirit week and for Halloween. This was for Toy Story Day at my school.
To make Mr. Potato head, I mostly used cardboard and lots and lots of glue gun. The frame is made of horizontal rings of cardboard and vertical reinforcements. On some of the crucial rings, I ran light wire through the cardboard by making two identical strips and glue gunning them together with the wire in the middle.
After making the frame, I used an old sheet and tucked the wrinkles in at the bottom and the top. Then, I painted the costume with a huge bottle of the cheapest acrylic paint I could find. The ears and nose are painted cardboard held on my glue gun. For the ears, I also cut slits in the main costume with flaps glued in inside.
The hat is made of 2 pieces. The hat base is just a piece of cardboard cut to a circle. The top of the hat is made of cardboard rings enforced with wire, just like the main costume. Both were then covered in garbage bag material.
For the shoes, I took a pair of old tennis shoes and made them longer by gluing cardboard onto the sides. Then I covered them with blue paper and cut holes for the laces. The holes at the top of the costume are eye holes.
I did this costume is two days and besides waiting for the paint to dry, it was pretty straightforward.