These DIY Mr and Mrs Potato Head Costumes were super simple to make and only cost me $8.97 in tan felt.  All of the other items I had on hand! How awesome is that? If you’re looking for a fun and comfy couples costume, keep reading!
Easy to Make Mr & Mrs Potato Head Costumes
Ready to make these Mr & Mrs Potato Head Costumes? Let’s get started!


72″ wide Tan Felt – 3 yards
1/2″ Elastic
3 sheets 9×12 pink felt
1 sheet 9×12 red felt
2 sheets 9×12 black felt
5 sheets 9×12 white felt
1 sheet 9×12 orange felt
1 sheet 9×12 light blue felt
2 sheets 9×12 green felt
1 sheet 9×12 purple felt
Sewing Machine
Hot Glue Gun
Safety Pin
Several sheets of copy paper
Pipe Cleaner
To start, you need to determine the height of the costume. Measure from the shoulder to mid-calf of the person wearing the costume and then add 2″.
DIY Potato Head Costumes
Fold the large piece of tan felt in half and mark the length you need.
Cut straight across.  It is now a xx”H x 72″W piece of felt.
Next, we need to add shape to it. First, measure the shoulders of the wearer, edge to edge.
DIY Potato Head Costumes
With the felt folded in half, mark the center.  Mark on either side 1/2 of your shoulder measurement – example: shoulder measurement is 20″ so mark 10″ from the fold on either side.   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 person’s butt) and then I rounded it off, 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.
We now have the front and back pieces of the potato cut.
DIY Potato Head Costumes
Let’s create Arm Holes!
Hold the cut fabric up to the wearer’s body and mark where you want the arms and head to be.
Time to add the ears.
Fold a 9×12 sheet of pink felt in half and free cut the ears. If you aren’t comfortable freestyling, I recommend drawing a template on paper first and using that to cut the felt.
Pin ears about an inch below the arm hole – making sure that they are pointing in and are sandwiched between the two tan pieces of felt.
DIY Potato Head Costumes
Time to sew!
If you don’t have a sewing machine, a hot glue gun would work ok too!
Starting at the edge of the neck hole, sew across the shoulder and down to the top of the armhole and then backstitch.
Start again at the bottom of the armhole and go all the way down to the bottom. Repeat on the other side.
I didn’t want, um… headlights, so I put the ears BELOW my arms so that the face was further down the body.
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 at 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 the 3″ gap closed.
If you want to finish off the neck and armholes 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 by adding a rounded seam and trimming the excess fabric. Flip right side out and the head is done!
DIY Potato Head Costumes
Next up – adding 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 happy with the faces, I traced them onto sheets of felt and cut them out.
 I considered gluing the face pieces to velcro so that they could be arranged which I think would be hilarious, but since we had planned on wearing these at an amusement park I didn’t want to chance losing anything.
Want to add a bow for Mrs. Potato Head?
DIY Potato Head Costumes
Take a 9×12 sheet of craft felt and fold it in half.
Using a pipe cleaner, wrap it around the middle of the felt, creating a bow shape.
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 DIY Mr & Mrs Potato Head Costumes to the Halloween Party at Disney World and received so many compliments!

Potato Head Couples Halloween CostumesDo you see my daughter’s Little Mermaid Costume above? I have a tutorial for that as well!

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