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.

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Step 1: 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:

Cover the entire head with tape.

Step 3: 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

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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Glue Contest

Participated in the
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Halloween Costume Contest

Participated in the
Halloween Costume Contest

8 People Made This Project!


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49 Discussions


3 years ago

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!

1 reply

Reply 2 months ago

I’m in the same boat- were you able to find the rest of the instructions?


Question 4 months ago on Introduction

I just paid $50 to get Premium on Instructables so I could get the pattern for Olaf. I can't find it. I REALLY need it ASAP. Would you please help me? Thanks! :)


Question 9 months ago on Introduction

where do i get the face template from the rest we can make from you very bad instructions but paid for nothing to see there are no extra instructions to download


2 years ago

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

Keala N DerekA

3 years ago

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


3 years ago

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!


3 years ago on Introduction

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!


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?


4 years ago

@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!


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!

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.


4 years ago

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!

1 reply

4 years ago on Introduction

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


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:


4 years ago on Introduction

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.