These Mr and Mrs Potato Head Costumes were super simple and only cost me $8.97 (for the tan felt).  All other items I had on hand.  Even so, the only other must haves are elastic, hot glue gun/sticks and felt sheets for facial features.
Easy to Make Mr & Mrs Potato Head Costumes
Want to make a set? Let’s get started!
 
SUPPLIES:
72″ wide Tan Felt – 3 yards
1/2″ Elastic
3 sheets pink felt
1 sheet red felt
2 sheets black felt
5 sheets white felt
1 sheet orange felt
1 sheet light blue felt
2 sheets green felt
1 sheet purple felt
Scissors
Sewing Machine
Hot Glue Gun
Safety Pin
Several sheets of copy paper
Headband
Pipe Cleaner
 
Instructions:
To start, you need to measure the height of your costume. For my husband, who is 6’4″ I measured from his shoulder to mid calf and then added 2″ for a total of 52″.  My final measurement came in at 45″.
DIY Potato Head Costumes
Fold the felt in half and mark the length you need (52″ for hubby).  Cut straight across.  You now have a 52″ x 72″ piece of felt.
 
Now that you have the felt cut to size we need to shape it. To figure out how wide to make it measure the edge of the wearers shoulder to edge of the other shoulder.
DIY Potato Head Costumes
With the felt folded in half, mark the center.  Noq we will mark on either side for your measurement – example: My husbands shoulders measurement was 20″ so I marked 10″ from the fold.   The above picture shows the measurement when the fabric is unfolded.
DIY Potato Head Costumes
Keeping the fabric folded in half you are going to cut a semi-potato shape, starting from the 10″ mark.  I slowly angled out until I got to the spot where I wanted my widest point (around a persons bottom – so 24″ for my hubby) and then I rounded it off and down and in until I got to the bottom.  See picture above for shape – left is how I cut it folded and right shows it unfolded.  You should now have the front and back pieces of the potato cut.
 
DIY Potato Head Costumes
 
Now it’s time to create Arm Holes. Hold the cut fabric up to the persons body and mark where you will want your arm and head to be.
 
Next, we need to add the ears. I folded a sheet of pink felt in half and then free cut the ears, but if you aren’t comfortable doing so, you can draw up a template on paper first. Pin your ears about an inch below your arm hole – making sure that they are pointing in and are sandwiched between the two tan pieces of felt.  
DIY Potato Head Costumes
Now it is time to sew, though if you don’t have a sewing machine, a hot glue gun would work ok too! Starting at the edge of your neck hole, sew across the shoulder and down to the top of your arm hole and then back stitch. Start again at the bottom of the arm hole and go all the way down to the bottom. Repeat for the other side.
 
I didn’t want, um… headlights, so I put the ears BELOW my arms so that the face was further down.
DIY Potato Head Costumes
Next, fold the bottom of the costume up 1 inch all the way around to create a casing for the elastic.Starting on a side seam, sew the casing, leaving a 3″ gap to insert the elastic.
 
Using a safety pin, thread the elastic through the casing. Use a zig zag stitch and sew the two ends of the elastic together. Sew shut your gap.If you want to finish off the neck and arm holes just fold the fabric in a half inch and either sew or hot glue in place.
DIY Potato Head Costumes
I also chose to round off the shoulders at this point but adding a rounded seam and trimming the excess fabric. Flip right side out and your base is done!
DIY Potato Head Costumes
The next step is to add facial features.  I drew up all of my facial features on paper and arranged them on the potato – this helped me size everything correctly.
DIY Mrs Potato Head Costumes
DIY Mr Potato Head Costume
Once I was happy with the faces, I traced them onto sheets of felt and cut them out.  I made my husband put on his potato and then hot glued everything into place.  I did consider gluing them to velcro so that the pieces could be arranged which I think would be hilarious, but since we will be wearing these at an amusement park I didn’t want to chance loosing anything.
 
Want to add a bow for Mrs. Potato Head?
DIY Potato Head Costumes
Take a small sheet of craft felt and fold it in half.Use a pipe cleaner to wrap around the middle creating a bow shape and then secure to a headband with the pipe cleaner.
DIY Potato Head Costumes
Cut a small piece of felt and wrap it around the bow and pipe cleaner and hot glue in place.
DIY Mr Potato Head Costume
DIY Mrs Potato Head Costume

 We wore these babies to the Halloween Party at Disney World and received so many compliments!

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