These costumes involve sewing so you will need a sewing machine to make them. Mike and Sully were fairly easy to sew, Boo was a little more difficult.
- Lime Green Fleece blanket - $2.88 at Walmart
- 1 Blue, 2 Black, 2 White Felt Squares
- Fabric Glue
- Sewing Machine and Thread (lime green, black and white)
- Tank Dress - Optional
1. I folded the fleece blanket in half and laid a tank dress I had on top of it. Make sure to line the shoulders up with the fold of the blanket. I then traced the top part of the dress (neck and arm holes) and the bottom line. This way it will be the same length and fit in the arms like your dress. Once you have those marked, connect the bottom of the arms to the line you made for the bottom of the dress by making a circle. Cut the neck line, bottom line and along the side, leaving the fold (shoulders) still attached.
2. Once it is cut out, turn it inside out and sew the two edges together (sides). Just sew from the bottom of your arm hole to the bottom of the fabric on both sides.
3. Leaving your costume inside out, fold the bottom edges inward and sew around it. Repeat for both arm holes and the neck. This will keep the fabric from unraveling since it's been cut. Turn it right side out once finished.
4. Create Mike's eye, mouth and eyebrow out of felt. Cut the shapes you want out of the felt then glue them to the other shape using fabric glue. Let it dry completely before moving or it won't stick.
5. I then sewed the eye and mouth onto my costume to make it stay because I wasn't sure the glue would hold the eye since it had 4 layers of felt. You can add Mike's horns to your shoulders if you want to but I chose not to.
6. I wore black leggings and a black long sleeve shirt under my Mike Costume.
- Light Blue Fleece blanket - I already had one I didn't use
- 2 Purple Felt Squares
- Aluminum Foil
- Fabric Glue
- Sewing Machine and Blue Thread
1. I measured my husband. Make sure to measure torso length, around the arms, distance from shoulders to top of head, etc...
2. I folded the fleece blanket in half and marked my husbands measurements. Cut the neck line, bottom line and along the side, leaving the fold (shoulders) still attached.
3. Once it is cut out, turn it inside out and sew the two edges together (sides). Just sew from the bottom of the arm hole to the bottom of the fabric on both sides.
4. Leaving your costume inside out, fold the bottom edges inward and sew around it. Repeat for both arm holes and the neck. This will keep the fabric from unraveling since it's been cut. Turn it right side out once finished. This piece should look kind of like a sweater vest.
5. Create your hood. I folded the left over fleece and cut out a quarter circle using the measurements I took from the shoulder to top of head. Because your fabric was folded you should have two pieces. lay then so the top sides are facing each other and sew the rounded parts together. Turn it right side up and attach it to the backside of your first piece. Once it's wear you want it, sew it onto the first piece.
6. Create your tail. I used leftover fabric for Sully's tail but you can use whatever you want. I basically sews the edges of he leftover material together to form a long triangle shape. I then stuffed the tail with all the scrap fabric I had (it was going in the trash anyway) and closed it by sewing it shut. I had to hand stitch the tail onto the rest of the costume because it was so thick and I didn't have the proper sewing needle to go through it.
7. Cut out a bunch of odd shape circles from the felt then glue them all over Sully's body except for his stomach using the fabric glue. Let it dry completely before moving or it won't stick.
8. Create Sully's horns. I used aluminum foil and molded it into the shape I wanted then I hand sewed it onto the hood of the costume. Don't stick the needle to close to the bottom of the aluminum foil or it will rip off, make sure you sew it higher or up through the center of the horn.
9. My husband wore jeans and a light blue shirt under his Sully Costume.
- 1 yard Solid Purple Fabric
- 1 yard of sequin purple fabric
- White Felt - leftover from Mike's costume
- 1 Black Pipe Cleaners
- 2 Foam Balls - $1 Pack at Dollar Tree
- Black Paint
- Hot Glue Gun
- Mop - $1 at Dollar Tree
- Sewing Machine and Thread (purple and white)
How To: This was made for a 10 month old.
1. For Boo I basically made a small sleeping bag but didn't sew the bottom. I measured my daughter and cut out a big rectangle shape out of both fabrics and the batting.
2. Sew the batting onto the solid purple rectangle.
3. Pin the Sequin fabric facing the purple fabric and sew all the way around, leaving a little space to flip in inside out. Once it is sewed, flip it inside out so the batting is now on the inside. Sew it closed.
4. You can't really tell in the pictures but I sewed two lines across (horizontal of the body) to make for the "puffy" look that is on Boo's original costume.
5. Fold the rectangle in half, hamburger style, so the solid purple if facing outward. Sew it together. It will be really thick so be careful and go slow. This seem was the back of Boo's costume.
6. Create Boo's hood: I originally made the body to small so I just cut it and used it as my hood. You can cut a 2 quarter circles and attache them or make it however you want. My hood was also lined with batting. Attach it to the back of the body you made.
7. Once the costume was put together I tried it on my daughter to get a feel of where her arms would be. I them cut two circles out of the body to create arm holes. I the turned the costume inside out, folded the arm holes toward me and sewed around them to prevent to from unraveling.
8. I then took 2 foam balls and painted them to look like eyes. Let Dry.
9. While the eyes were drying I cut 5 teeth out of left over white felt from making Mike. I then hand sewed the teeth were I wanted them. Make sure they are spaced out and not blocking your daughters eye sight. You can add these on at the begging before you sew the purple together but I didn't because I wasn't sure where I wanted them until I saw it on my daughter.
10. Attach Boo's eyes: I took 1 black pipe cleaner, bent it and hand sewed it in the middle of Boo's hood. I pretty much tacked it so it wouldn't fall. I poked a small hole in the bottom of the eyes, filled it with hot glue and stuck the pipe cleaner ends in the holes.
11. Boo's hair: I pulled a few strands from a mop I bought at the Dollar Tree, placed them where I wanted them and tacked them onto the hood, covering where I tacked the pipe cleaner. The more you put on the heavier it will make the hood so don't add a lot. I used about a third of the mop if even.
12. My daughter wore a purple onesie and gray pants under her Boo costume. It was freezing Halloween night so we put purple gloves and a purple hat we already had on her to keep her warm. The hat helped keep the up.
This is how I decided to make Mike, Sully & Boo but there are several other ways to make these costumes. You could do something simple like painting their faces on a t-shirt, use a different fabric, or buy your own at a costume store. I'm sorry if the costume tutorials are a little confusing. It's hard to describe how I created them and make it make sense without pictures. I hope you enjoyed this tutorial. Feel free to comment below with your homemade Monster's Inc. Costumes!