Introduction: Frozen Olaf Costume ( New Instructions)

Picture of Frozen Olaf Costume ( New Instructions)

Ladies and Gentlemen, Introducing ................Olaf and Marshmallow the endearing snowmen from Frozen!
My latest costume inspiration came from the popular Frozen movie. I wanted to make a costume that my grandchild and I could wear together. Frozen is her latest obsession and she loves the Olaf character.

The Olaf costume is super lightweight and comfy for my grandchild and has good visibility. The base of the costume headpiece is butcher paper and duct tape. The base is covered with a layer of batting and then a top layer fleece fabric. There are craft foam eyes and a fleece nose. The body is tulle tied onto a crochet band at the top and a small hula hoop at the bottom. The body was then covered with fleece . I used a thrift store t-shirt for a liner so the scratchy tulle doesn't come into contact with skin. I am proud to say it is one of the most comfortable costumes I have ever made!

All the pieces were glued together using a silicon cement from the hardware store . The cement is strong ,flexible and waterproof.


In an effort to make the costume easier for others to replicate, I had to go backwards and make a pattern after the costume was complete. I had no idea that it would come out so well. I surprised myself!

The pattern pieces can be used for all layers. First cut the pattern out of stiff paper like butcher paper. I used a roll of brown paper from the home improvement store. Using lots of duct tape I rounded out the shape. This is by far the most tedious step, but if everything is in the right shape and proportion after this step then the rest will be easy. Sometimes at this step I will have to enhance some areas by added a little more paper or tape or a may have to trim away with scissors if some part is too large. This step took a couple of hours before I was satisfied with the look and expression that I imagined Olaf would have.

When you are satisfied with this step then cut out front and back pattern pieces from batting ( found at fabric stores). Form this over the paper and tape base making sure that everything is very smooth. trim away any excess so that the area where the pieces meet is as seamless as you can make it. This step is solely for the purpose of giving your finished product a smooth texture. This is the step where you want to eliminate any imperfections. Make sure everything is symetrical at this point. I either use loose stitches to hand sew the sections together or I use glue.

For the top layer use fleece fabric and cut out the front and back pieces. Repeat the same process as with the batted layer. I would definitely hand sew the pieces together after formed over the headpiece.

Make the lining bu cutting out 2 lining pieces from the fleece. Sew the 2 pieces together across the top and at under the chin area. leave the face and neck open. Put his inside the head and hand sew the mouth section of the lining and the top layer of fleece over the headpiece together. Also, hand sew the neck and back opening to the top fleece. At this point looking inside you should only see the lining. The paper and tape should be covered.

The nose is cut from fleece and stuffed with polyfill. It is sew into position on the head

The eyes , eyebrows and hair are made of craft foam that I painted and glued on. For stability I glued wire to the back of the hair to keep in erect.

Step 1: Paper /Duct Tape Base

Picture of Paper /Duct Tape Base

You can stuff a bag or fabric with newspaper or stuffing to make a form to work over.

Cut 2 pieces of paper in the outline of the headpiece. Tape the sides together over the form.

Tape all the way around except for the neck opening.

Cut out a mouth. Cut 1 rounded rectangle about half the size of the head for the nose and upper lip..Snip the bottom lip edge with 1 1/2inch cuts. Round in the lip of the paper and tape in shape.

Tape this mouth/nose extension onto the face.

Step 2:

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Cover the entire head with tape.

Step 3: Inner Body

Picture of Inner Body

I made a body form out of duct tape in my child's size , but you could use a pillow instead.

For the costume's body lining start with a plain white t-shirt.

Construct the tulle layer:

Buy a white crochet headband.

Cut 4inch wide strips of tulle. The length of the tulle should be about the length of the wearer's body measured from the shoulder to the floor x2. The tulle is then folded in half and looped through the bottom row of the headband.Go all the way around the headband looping tulle in all the spaces/holes in the bottom row of the headband.

Buy a hula hoop. The hoop can be opened by removing the tape/staple seam and pulling the hoop open. Resize the hoop to be slightly wider than the wearer's shoulders. A serrated knife works well for cutting the hula hoop. Retape the hoop closed .

Tie the loose ends of the tulle to the hoop . Try to keep the length and tension equal all the way around.Turn the loose ends to the inside of the costume. Tie one piece of tulle at the waist to cinch it in.

Cut 2 rectangles of quilt batting . One will cover the chest area and one will cover the stomach /leg area. The top rectangle has arm openings at the sides . Measure the arm opening of a t-shirt that fits the wearer comfortably and use that as a gauge for how large to make the costume arm openings. I usually add an extra 2 inches to make sure the costume is comfortable.

The top rectangle of batting goes at the top third of the costume above the waist. Wrap the batting around the top and cut it so that it meets smoothly in the back of the costume . Hand sew or glue closed at the shoulder area and the back.

Repeat for the bottom. The bottom is almost double the size of the top layer.

Step 4: Top Fleece Layer

Picture of Top Fleece Layer

The top layer of the costume is made exactly like the batting layer. I allow an extra inch around the fleece pieces so that I have extra fabric to roll inward.

With the t-shirt base covered with the tulle/batting layer and then topped with the fleece top layer, I check to see if everything is smooth and all the openings in the different layers meet .

The top layer and the lining are now hand sewn together trapping the tulle layer inside.

Glue or sew the top section to the bottom section.

Now you will need to cut an opening through all the layers .At the back of the costume at the neck edge cut an opening in the exact center about 1/2 of the way down . Hand sew the edges of the opening. Place a large snap at he neck .

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CarolinaS37 made it! (author)2017-02-26

Not the same, but not so bad either. My daughter just won 1st prize on Carnival contest with it. And she loved it!!!

gbunning (author)2016-09-04

Anyone find the rest of the steps? I guess I will just wing it! Such a cute tutorial!

KennethY6 (author)2016-03-02

Hi everybody! I need to make an adult Olaf costume by next Friday. Can anyone provide me with all of the steps? My email is Thanks in advance!

jerry.eversman made it! (author)2015-11-23

I made the Olaf costume using these general instructions and adapted to materials I had on hand to make the head. I used a boys batting helmet that I got at a thrift shop to fit over the human head. I used styrofoam around the base of the helmet to help form the outline of Olaf. With a brand new white sweat shirt and pant and all the trimmings, we had a larger than life...Olaf.

KimberlyW17 made it! (author)2015-10-23

Thanks for the instructions. I made this last year when the granddaughters wanted to be elsa and ana. It was a huge hit .But very hot for georgia. Thank goodness this year we are going to be superheros. I think my Super Grandma costume will be alot cooler...

Keala N DerekA (author)2015-10-16

Aloha my daughters are dressing up as Ana and Elsa. They told me that I need to be Olaf. Your costume is amazing. Could you please email me the steps.

Mahalo from maui

RobertM75 made it! (author)2015-10-06

Thanks for your instructions on how you made Olaf. Yours were the only instructions I found. I made one for my 5 year old and am pleased with how it turned out. My children decided to be Anna and Olaf this year for Halloween to have costumes to go together. I am planning on adding feet for him but just haven't gotten there yet.

StephanieA17 (author)2015-10-01

I'm thinking I'm dense, but where is the pattern for this? I would love to make this for my 2 year old for halloween! Or is that part of the pro subscription deal? Thanks!

LiveCrafts (author)2015-08-28

My mom and grandma made one of these for me...I love Olaf from Frozen, and everyone was so shocked and so amazed when I walked into school for the halloween parade. It was incredible. I'm going to wear it again this year. Thanks for the instructions, because of this, I had the best halloween ever!

rebecca227 (author)2015-06-26

Where is step 5?

Queenkat made it! (author)2015-04-20

I'm ecstatic with how he came out! Thank you! If anyone wants to see my process just message me.

henry.cook.52 (author)Queenkat 2015-04-23

Could you please send me your process? I would love to make this for our spring choir concert!

Queenkat (author)henry.cook.522015-04-30

Hello, I'm glad you're thinking of making one! My pictures are posted on my profile. I'm working on editing my pics of the body I will put those up soon. If you want more details message me.

poundcake90303 (author)Queenkat 2015-04-22

Queenkat if could email me the steps at i would greatly appreciate it! !

poundcake90303 (author)Queenkat 2015-04-22

@queenkat please show me your process!

henry.cook.52 (author)2015-04-23

Would love to make this for our spring choir concert since it is Disney themed! i cant see any of the steps after step 4. Would you please email them to me?

poundcake90303 (author)2015-04-01

@darcy3529 i just saw this and would like to make it but i can't seem to see all the instructions. If you can give them to me i would greatly appreciate it. Thanks.... my email is .. only the head instructions!

jackie.c.williamson.1 made it! (author)2014-11-01

Mine wasn't as good as yours, my mouth could have been bigger and less wrinkled but everyone was amazed with it. I used pipe cleaners for the hair and added another hula hoop at the waist line. I also made boots. The kids went crazy over it for Halloween. I spent 10 hours on the head and 8 hours on the body and boots. Thanks for the instructions. Everyone wants to borrow it now but I think it is custom made for me. Since it was an adult size I also glued some tricot onto the bottom of the tshirt so it wasn't scratchy on my legs.

I am attempting to make an Olaf costume. I am not exactly a super crafty person. So this endeavor is a leap of faith. I am trying to make Olaf adult costume. Do you have dimensions of olaf's head that you could share?

The height was 21.5. I think it is a little too tall. The width at the cheek was 17.5 and the width at the bottom was 13 across. We got asked to be at the half time of the local university in this and Elsa's costume so even though I didn't think it was perfect, someone liked it!
I also took an ice cream tub and cut it off and glued it inside the bottom to keep the rounded shape.

Thanks for posting photos! Your adult Olaf looks incredible!

СергейБ (author)2014-11-17

Where is step 5?

СергейБ (author)2014-11-17

Where are all the steps? I only see 4 .

marla.pulkrabek made it! (author)2014-11-12

Hi I logged in before as JefferyP1 but I am Marla, an owner of a small custom sewing business called RiverHouse ArtHouse and I made one of these for my 8 year old. It too was a smashing hit in the town and won a prize. And she felt like a star of the parade! I made a scarf to wrap around neck that said "I love Warm Hugs" and every little child who passed was in awe and had to hug "Olaf" Thank you for the inspiration and DIY ideas you first posted a month ago, as that helped me get started. I chose to use a sleeveless tshirt and an old under wire netting thing from a princess costume as my under side so i didnt even need any other lining. I was a hit. Thanks again for sharing.

rarumy made it! (author)2014-11-02

THANK YOU FOR THE BEST COSTUME EVER. I had to make mine for an eight year old, was a little more complicated. Lots of patience and lots of time, but well worth it! I think I had over 20 hours into it :) And I still like Olaf!

darcy3529 (author)rarumy2014-11-06

YAY!! SWeet! I love seeing how your Olaf came out!Good Job.

lori.berg.509 (author)2014-11-03

I would love to make the costume but I am only able to see up to step 4. Is there something I need to be doing to see the remainder of the steps??? Thank you in advance!

jackie.c.williamson.1 (author)2014-10-30

Thanks, yours was the only DIY that looked like Olaf. I especially love him with the sunglasses and hula skirt. My mouth didn't turn out nearly as good as yours - a few more wrinkles but nobody but me really notices. It took me two full days to make an adult sized one but going to enjoy it tomorrow for Halloween along with Elsa and some wolves! Thanks.

brenda.deweeshyde (author)2014-10-19

Missing steps 3-43. Just made the head and was wondering if there are any further instructions you can send on how to form the body? We've made the tulle and hula hoop part, just looking for further direction on how to finish it. Thanks!

If you have further instructions please email

momaG13 (author)2014-10-26

Great costume! We are all still waiting on the instructions!!

joann.sweeney (author)2014-10-24

I can only see up to step 4 now. If anyone can view more than that can you PLEASE copy photos and directions and sent to me to:

vicky77 (author)2014-10-23

Hi again Darcy, there are no instructions for that batting and fleece on the face. I see a cut out, but it doesn't explain the seem on the front underneath the mouth. Were you finished with the instructions for it? Has anybody else made the entire face yet? Thank you again Darcy for posting more of the instructions on the body.

joann.sweeney (author)2014-10-20

Hi Darcy, I also got into the instructables and it only shows 2 steps and missing all the rest. Hopefully there is a better place where you can post the pictures and instructions. Your Olfa is the best!

Thanks for your time in posting them and helping us.

Greatly appreciate it, JoAnn :)

darcy3529 (author)2014-10-20

Sorry about the body instructions. I am working on a better set of body instructions and hope to have them up in a day or two.

Kristiebash (author)2014-10-18

Hello! I just purchased the Pro Membership and there are no instructions past step #2 in the downloaded PDF. How can I get these? I think I can figure it out from the remaining instructions however, I purchased the membership hoping that I would get full instructions in case I get stuck. Please send me an email if possible with the remaining instructions. I have already started this project and need to have it finished by Halloween.

vicky77 (author)Kristiebash2014-10-19

Kristiebash did you ever find out what happened? I paid for the membership, and I downloaded it , and there was NOTHING passed step 2. I am not happy :( My email is

Kristiebash (author)vicky772014-10-19

No, I have not heard back yet. I am pretty frustrated that I bought the membership and didn't need to as I got notbi g extra for it. My onlh thought is that maybe the gal who made this is not finished with the instructions yet???? Let me know if you find out more info and I will do the same.

nwiltshire (author)2014-10-18

Please could you help with the steps as the won't load. Do you have a link or can email design to me??

JEFFERYP1 (author)2014-10-14

thank you for all your info. you have provided great pictures and instructions for us to work from to get busy and start experimenting and estimating on our sizes. I personally will be using one of my kid 's really huge stuffed animal's heads to shape the Olaf head around, as i dont have a headform, and will modify it to look more like this as i go, as my child is 8. Look around your house or go to thrift store to get something(s) you can use, like a ball if necessary - as this designer stated it is trial and error, drawing and sculpting with tape, till you get it right. Enlarge his/her drawing photos if necessary and print out for yourself to use also could help. my first original attempt using pliable wire resulted in a mess so i am now going to use this procedure and can tell already it is the winning way. thanks again.

darcy3529 (author)JEFFERYP12014-10-16

Thanks! In the past I have tried using wire and other things for headpieces. This was the easiest method by far!

Tmolander (author)darcy35292014-10-16

But where is the pattern to download? I can't find it. I'm excited to make this

Klk61684 (author)2014-10-12

how did you make the head? This is absolutely great!!! any suggestions would be appreciated. Thank you!

gjjklwik (author)2014-10-11

where can I get the pattern? I downloaded instructions but can't seem to see the pattern.

SahaiS (author)2014-10-09

how much did it coast altogether?

marquess78 (author)2014-10-06

Mildly irritated that I cant download the pattern without spending money. Im making this literally right now. My body is finished but I need measurements for the head. I don't want to cut it too small. Can you give some dimensions or measurements please? Its for a 4 year old, my body is pretty close to the same size yours is. Thanks

joelle.curtispalise (author)2014-09-27

I am a preschool teacher and would love to make this for myself to entertain my class! I cannot get the instructions to download and my concern is the head. How did you get it to keep it's shape? Lots of duct tape? I cannot sew.....will hot glue do justice to this?

rebecca.piazza.16 (author)2014-09-26

I am hoping to make this (or something like it) for halloween for my son who is wearing size 12 month clothes right now. Would I be able to shrink the pattern down easily for this? I am hoping to buy it in the next few days as the fabric store by me is having a sale until the end of the month

darcy3529 (author)2014-09-25

Sorry for the confusion. I formed the head over a wig block , but a styrofoam head would work as well. The head is oversized ,however. Depending on the size of the wearer enlarge the pattern pieces accordingly. To get an idea of the size to make things you can stuff a shirt and pants that fit the person who will wear this and using newspaper of other large paper make a sample piece to get an idea of how large the pieces need to be. THe head is approximately a third of the total size of the costume . If you use a large sheet of butcher paper you can even have the person lay on top of the paper and draw a rough outline of Olaf around them to get the right proportions.

karen.males.7 (author)2014-09-24

How do I get the pattern printed? It won't allow me to download them. Thank you.

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