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DIY Olaf Costume Instructions

Posted on: by Kate
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DIY Olaf Costume Instructions

The Chest and Sleeves

diy olaf chest and sleeves

Olaf costume chest template

The chest is made up of 6 pieces of foam and fabric. The sleeves are made and added after the chest is partially assembled. Pay close attention to the pattern of the chest pieces on the template. You are making a front shape and a back shape. Note that you must add a triangle piece the back middle fabric. This should be done before you sew the side pieces on. See the image below.  You can sew the fabric or glue the foam first.

Olaf costume back template note

On each side of the front and back foam shapes should be half of the sleeve hole. Do not glue along the top or bottom. The foam can be fully glued (all 6 pieces) but the fabric should be kept in 2 pieces.(front and back) Each of these is made up of 2 pieces of fabric.

Sew the top of the shoulder area together- Front the neck hole to the sleeve hole. Do not sew down the sides yet.

Olaf costume sleeve template

Cut the sleeves out. Be sure to measure your child’s arm length and add 1 inch to it. Pin the sleeve according to the instructions on the template. Follow the sew pattern. You will sew the sleeve into the hole first. Continue by sewing the side seams of the chest from the bottom up. When you reach the armpit, sew down the sleeve seam. Repeat for the other side.

OK, moving onto the Gloves and buttons. These are next.


The gloves

Use the glove pattern to sew 2 gloves. There are no right or left gloves. Use the same pattern for both. Note that Olaf has 3 fingers and a thumb. You can add elastic if you wish. It took me 6 tries to get the gloves so do not rush these.

Olaf costume glove template

The Buttons

Using the button pattern and sew it into the half dome shape. Sew this onto the circle. Your buttons should look like half a coal shape after you stuff them. Cut a slit into the circle shape and stuff each of the 3 buttons. Wip stitch it close. You will need to hand sew it onto the chest and body pieces. Do this after the chest and body pieces are sewn together.

Olaf costume button template

Olaf-Costume-etsyOn the next page, we have the body. It is pretty easy to make but is a lot bigger than you might think.

Continue reading this article … Pages:  1 2 3

DIY Olaf Custom instructions and templates
Article Name
DIY Olaf Custom instructions and templates
Olaf Custom DIY instructions and template for Halloween.
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Highlights Along The Way
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Until Next Time ~ Kate
Comments: 24 Responses
  1. Wolf says:

    Thank you so so so very much for sharing these patterns and instructions. They are very informative and well written. The only glitch is that the leg picture is not a link, it will not lead to a bigger picture, and it is kind of hard to read the instructions on the pattern. If this is not meant to enlarge then please ignore my comment lol. Again, thank you so much for sharing. I am making an adult sized costume and I will definitely share your site!

  2. Jean says:

    Wow thanks!! These look great! My son will be thrilled!!

  3. Katie says:

    I might just have to make that!! That is awesome!

  4. Theresa says:

    Thank you so much! You have just saved me!! Now I gotta get going n make this costume…I just hope it turns out half as good as yours! P.S. If I can’t afford that furniture foam, what else would you recommend? Some type of Quilting foam?

    • Kate Hamernik says:

      Theresa – I am sure that would work, he chose the furniture foam bc it made it much sturdier and he really wanted the body to poof out well – quilting foam will work it just wont be as sturdy – honestly this was a much more expensive project than we anticipated and I would suggest making something more budget friendly 😉 have fun!

  5. mike says:

    Great job super-dad!!! I was in the same boat when my daughter saw Maleficent and decided daddy would make her the young Maleficent with actual working wings!!!! It turned out almost as good as your Olaf outfit! What we can’t and won’t create and do for our kids huh? Lol Congrats again.

  6. Scott Pitner says:

    Thanks for this great DIY instructions! I successfully followed the steps and recreated Olaf for my son for Halloween this year. It was a smash hit! You’re right, it definitely IS time consuming! I spent probably close to 40 hours on it, and that doesn’t include the 6 or so hours my wife also spent with me on it. I didn’t quite finish – I didn’t make the arms or gloves. I also had to rush attaching some of the stuff on the face – hot glue gun to the rescue!

    I have a bunch of suggestions if you are interested in updating these templates at all. The easiest one would be to include a template for the “hair” on the top of Olaf’s head! I still need to make those for my son’s costume, but nobody really noticed it was missing anyway 😉

    Will find your email and send some pictures!

    • Kate Hamernik says:

      Scott – I am SO excited to see pics! Yes! We would love to update our templates and it would be helpful – Harry was VERY rushed when making the template (once people saw the costume they were asking for instructions and that was never his plan, so it was rushed) – I bet your son had so much fun! email =)

  7. Tania N. says:

    So cute 🙂

  8. Stefanie says:

    Love this costume! I was wandering what kind of bike helmet you used 🙂 Was it one of those that look like a skate helmet?

  9. Andrew says:

    Hi there,
    Thanks for the instruction. I am making this for a play for our company annual dinner. The muzzle part and the head, which part glue where? This part i cant manage to get it… I also make some amendment on the upper part of the body as it seems too short for me..

  10. Andra says:

    Where do you buy the craft foam?

  11. April Loudner-Maffin says:

    Thank you so much for sharing your hard work. I am costuming Frozen Jr. for our community theater in December and really wanted to make Olaf rather than buy the costume. His head was the piece I was most concerned about. I must be missing something, but I am unable to find the second page. I keep scrolling up and down, but I don’t see the next button like I saw to get here. Can you possibly help me with that? I feel like a dork, lol.

  12. Kim says:

    Fantastic – this is GREAT – I love the “head” What is the size you recommend when printing the template?

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