Tuesday, October 21, 2014

Marshmallow From Frozen Costume Tutorial

Last January when we were discussing our Family Theme for Halloween, (I like to plan at least 9 months in advance because I am crazy like that) I suggested Lord of the Rings, Avengers, or Star Wars. With three sons I wanted to pick a theme they would like. I still can't believe they were willing to dress with a family theme when our oldest is 9! I guess they have never thought they could choose their own thing. I hope we can keep this tradition alive because I love it.

Well the boys chose Frozen, which surprised me. But the only problem was who my 2nd son would be. I told them if we couldn't work it out we would have to choose a new theme. He really wanted to be Olaf, but my youngest boy really loved Olaf too! And the previous year when my youngest wanted to be Peter Pan he had to be Michael, because I wasn't going to make my 5 year old wear pink to school. I suggest Sven but he told me my drawing was "lame". Finally my little "Draco" chose Marshmallow. He loved the idea of being his sister's protector. And he wanted to be the Marshmallow version with the spikes. Way cooler. I wanted to make it as cool as possible.

Draco loves sewing. He loves watching me sew. And he thinks I can sew anything. I love sewing for him because he gets so excited, even if it's not for him. When I was sewing my costume he told me it looked so beautiful in just the sweetest voice.

So let's get started!


White material ( I choose fleece leftover from our Olaf Costume)
Long sleeve white shirt in a bit of a bigger size
Blue felt
Blue material for the spikes
sewing machine

I started with fleece folded so I could cut two pieces for his hat. (See picture) You trace your child's head and add extra for seam allowance. My son recognized this pattern from when I made our pikcachu costume two years ago. I use it all the time. Make sure to leave tabs so you can wrap it around your child's neck. Sew the two pieces together, right sides together. Turn it out and try it on. My boys always love that part.

Cut teeth with your fleece. (See picture) Sew the teeth to your hat. Cut out eyes from your blue felt. Glue them on with Fabric Tac. I like doing it while they are wearing the hat. Sew Velcro on the straps so you can wrap it around their face.

I take a pair of PJ bottoms and use it as a pattern. You want to cut out two legs on folded material so you can cut two. (See picture) I tapered the legs because Marshmallow has bigger legs. Also leave some extra space on top to make your elastic casing. With right sides together you want to sew the legs together at the sides, but not the crotch part. Then when you have done this to both legs, turn one of the legs right side out. Then slide it into the wrong side of the leg. (See picture) Sew along the crotch. You can even reinforce that seam and go over the middle again. Turn them out the right way.

To make the casing you first need to get some elastic and put it around your child's waist. Pull it a bit tight. Fold over your fabric a good inch and sew around to create a gap. Leave a small hole by not completing your stitch back where you started but leaving some space. Take a safety pin and attach it to your elastic. Push it through your gap in your pants. Pull the elastic out, but not all the way. Undo the safety pin and sew the elastic together. Then finish off the seam so your line connects. I didn't hem my pants to keep things simple. (yay for fleece!)

I love my Fiskars mat! I love cutting material on my bed if my baby is around. And I love the mats great size. I used my rotary blade and mat to cut my spikes. I wouldn't recommend this material because it frayss so easily, but I had it from my baby girls Elsa costume. And I love being thrifty. My mat had a great triangle that I used to help me keep the spikes the same size and angle. I purposely made the ends of the triangle the selvage edge so it wouldn't fray. I cut two of each spike and sew them together. Then I zig zagged the edges so they wouldn't fray on me. Next I cut some foam I had leftover from Little brothers Penguin costume. I was going to use wire too, but I really didn't need it. My son wanted two spikes on each shoulder. I was happy with the small amount requested as I still have so much to sew. Feel free to make more.

Once my spikes were done, (See picture) I folded over the small side like a present and with the sewing machine sew a long side to his shirt. I then hand sew the rest of it on. Repeat with all your spikes, taking care to match them up. Then I cut four rectangle foam pieces and 1 long rectangle. I put two foam pieces where his shoulders are to create bulk. And then added the long piece across his chest. He loved feeling buff.

"Oh hi, we were just talking about you. All good things, all good things!"

He is such a joy to sew for. He loves to watch me, but and he insisted I was doing it wrong. He warned me I would have to do it over again. When I finished his hat it blew his mind that it turned out. Can't wait for him to want to learn how to sew.  The boys had so much fun taking pictures together!

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Thanks so much for reading...


  1. THANK YOU!!! I had to make a simple Marshmallow costume for my kid who is in a Frozen play and I had very little time. Your instructions saved me, I was able to pull this together in about an hour, (and I had all the materials leftover from last Halloween's Frozen projects of Elsa and Olaf too!).