The Pizza Costume

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All Photos by Jenn Newgent

I usually get a gazillion ideas for Halloween costumes and our son has a gazillion different ideas. Sometimes the plans can get pretty elaborate, but they often don’t get made. That’s one of the drawbacks of being an idea person.

This year he went through the gamut of ideas and he first settled on being a bag of pretzel M&M’s. I sketched the whole thing out and started gathering materials. Then mass marketing hit his impressionable and constantly moving mind. The plans were changed to Buzz Lightyear.

Not wanting to spend $40 or more to get a halfway decent looking costume, I started sketching. Let me tell you, there is no easy way to make a good looking Buzz Lightyear costume.

Happily, he discovered something he wanted even more on the Kmart web site, so this year we bought him a costume. He will be going as a $100 bill.

Wearing Your Food
The one costume that made it out of the sketchbook was when he was 3. He went as a slice of pizza. I mostly went with the idea because I knew I could put it together easily with a glue gun. Last year, when he was 5, he decided to wear it again. This is what I did…



  • Tan Vinyl
  • Red fabric–felt works well
  • Ivory Sheer Synthetic Fabric such as nylon
  • Computer print-outs  of pepperoni or other pizza toppings
  • Black paper for olives


  • Hot glue gun
  • Embossing gun or toaster
  • Circle punches

How to Make the Costume

  1. Make a pattern out of newspaper to determine the right size before cutting the vinyl. Be sure to cut open the neck and place a small slit in the back to make room for the head to go through.
  2. Cut the vinyl. Be careful when cutting the neck opening and back slit. You don’t want it to be too big. If the back slit flops open, glue some ribbon to each side to use as ties.
  3. Rough cut your red fabric to fit the front and hot glue it to the vinyl piece. Make sure to leave room for the crust edge to show.  Trim it clean around the edge. Put fray check on the edge to help with raveling. If you use felt for this, you won’t have to worry about fraying.
  4. You will need two layers of synthetic sheer fabric that are larger than your pizza slice. Synthetic fabrics are really plastic, so heat can do some interesting things. If you can, test several fabrics to see which ones melt the best.
  5. Use a rubber stamping embossing gun to heat each layer of the fabric pieces to make them look bubbly.
    If you don’t have an embossing gun, you can hold it above a heated toaster. This method is more tedious and has a greater risk of burning.
  6. Take the uncut pieces and hot glue each layer on to the costume making sure to fold down fabric at the crust edge. Trim the edges to fit. Use a candle or lighter to melt the edges to keep it from fraying. Be very careful.
  7. Find computer images of pizza toppings and print. I used glossy paper.  I used a  circle paper punch to get neater edges on the pepperoni images. Hand cut irregularly shaped images.
  8. Use two different sizes of circle punches and black paper to make the olives. Punch the small circle first and then the larger over it.
  9. Glue all of the toppings with a hot glue gun. Be sure to glue all of the the edges down. This will help keep it from creasing.
  10. Finish by gluing strips of  black elastic to keep the front and back panels in place.

If you have made an interesting costume, I’d love to hear about it.  Just leave a comment.   If you send a picture I’ll post it on the blog or in a photo gallery. My email is in the “Contact” section to the right.


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