Easy Disney DIY Mickey Mouse Costumes for Halloween

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Kids love dressing up as favorite Disney characters and Mickey Mouse is at the top of the list! Whether you're making Halloween costumes or dressing up for the theme parks, these DIY Mickey Mouse costumes feature three of Mickey's favorite looks.

DIY Mickey Mouse Costumes

In five years of trick-or-treating, my son has been Mickey Mouse three times! The first year was the classic Mickey (which he calls, "Happy Mickey"). Then Sorcerer Mickey. And this year, it's Mickey in his Roadster Racers costume.

As a big Disney fan, I love that my son wants to dress as his favorite character so often! And fortunately, Mickey has plenty of incarnations to choose from. Here's how you can make each of these three Mickey Mouse costumes on a budget at home.

Can Kids Dress Up at Theme Parks?

Yes, kids under 12 years old may dress in costume at Disneyland or Walt Disney World.

No need to wait until Mickey's Not-so-Scary-Halloween Party or the Oogie Boogie Bash. Costumes are able to be worn at any time in the Disney theme parks, so long as they meet the requirements. Check the websites ahead of your visit to ensure the costume is appropriate.

Why Make Your Own Costumes?

Crafting your own costumes can be more time consuming than purchasing ready-made costumes at the store or online. There are benefits to making your own DIY Mickey Mouse costumes.

Lower Cost

The cost difference when creating your own costumes can be beneficial when compared to store-bought costumes. Some items purchased for these costumes can be reused, including the unaltered clothing pieces.

Personalized to Your Child

When you sew your own costumes, they can be sized especially for your kid. Children often have their own thoughts about what unique style they'd like to see on their costume. You'll be able to personalize the look at your child's request.

For additional DIY costumes, I have a LOT more Halloween costume ideas HERE.

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Easy Shopping Links

No need to shop around, looking for the best items when putting together your DIY Mickey Mouse costumes! I've done the work for you and put together shopping lists for each costume!

Simply click the links in each section to shop when choosing items for the Mickey costumes. Or click the image below to find all the items in one place!

Classic Mickey Mouse Costume

This sweet Mickey Mouse costume is the easiest of the bunch! Several of these pieces can be inexpensively bought. There's minimal sewing here and the costume goes together quickly.

Items needed to create a Classic Mickey costume

• Black t-shirt, long sleeved or short sleeved
• Black leggings, optional in warm weather
• Red shorts
• White buttons, two large sized. Sew to the front of the shorts.
• Yellow shoes (but we settled for white!)
• Kid-sized Mouse Ears or DIY hood (instructions below)
• White gloves, optional in warm weather

Sew a Mickey Mouse Hood

1. To sew the hood, you'll need stretchy black fabric and poly-fil (polyester fiber stuffing). If you'd rather avoid the sewing project, purchase premade Mickey Mouse ears.

2. Choose a very stretchy fabric, like this stretch black velvet, sold by the yard. Choose a material you don't need to hem or finish off the edge. Most stretch knit fabrics won't fray.

3. For the Mickey hood, use this image as your guide when sizing to fit your child. You'll need to cut two pieces.

As a side note, the pattern template recommends using Velcro at the neck. I used such a stretchy material that I was able to skip this step.

If you choose a very stretchy knit, just sew the chin closed. You'll need to gauge whether or not your child will be able to pull the hood over their head or if you need to insert the Velcro closure.

4. For the Mouse ears, cut four circles about 5" in diameter with a notch on the bottom (they will look like a balloon shape). Sew two circles together, leaving the bottom open. Stuff the ears with poly-fil and pin shut.

5. Size the hood on your child, marking where the ears should go. Cut a small slit in the hood for each ear, then insert the bottom notch.

6. Sew on the ears by pinching the slit shut. Pin and sew a seam across to close the opening. Voila: Mouse ears!

The Sorcerer's Apprentice Mickey Mouse Costume

Isn't this Sorcerer Mickey Mouse costume Fantasmic!, err...fantastic?! This DIY Mickey costume is budget-friendly and fairly easy to make as well. It's all about the sorcerer hat, naturally. The rest of the costume is extremely easy to pull together last minute.

With the wave of your wand (and a few stitches on your sewing machine) you'll be able to sew up the Sorcerer's hat. This topper is the centerpiece of a showstopping DIY Mickey Mouse Halloween costume.

Items needed to create a Sorcerer Mickey costume

• Red over-sized t-shirt or tunic, short-sleeved
• Black t-shirt, long-sleeved
• Black leggings, optional in warm weather
• Brown rope belt to tie around the waist
• Brown shoes or Brown sandals
• Materials for the hat pattern (see next section)

How to Make a Mickey's Sorcerer's Hat

Yen Sid's sorcerer hat is the winning part of this DIY Mickey Mouse costume. Please read carefully through the instructions before beginning your project.

I have included several different options for creating this piece, including a no-sew method. You can choose how to create the hat, depending upon your skill level and craftiness.

These are the things you'll need for the sorcerer's hat

• Cone hat pattern, like this pattern for a "witch hat"
• Blue cotton fabric, I recommend Kona Cotton Broadcloth Fabric (One yard)
• White cotton fabric or felt for the stars & moons (One quarter-yard should be enough)
• Black felt for the Mouse ears
• Buckram, a stiff fabric-type material that will help the cone to stand up straight (half-yard would be plenty)
• Fusible bond, like Heat’n Bond Lite Iron-on Adhesive OR a Hot Glue Gun
• Poly-Fill stuffing

Instructions for Sorcerer Mickey Hat

1. Cut two pieces of blue cotton and one piece of buckram from the cone hat pattern. You'll only be cutting the cone part of the hat pattern.

2. Sandwich the buckram in between the two blue cotton pieces. Baste around the edge to hold all three pieces together.

3. Cut Mouse ears out of stiff black felt. Cut 2 simple circles with a tab on one side to attach to the hat (they will look like a balloon shape).

4. Curve the hat around your child's head to see where the placement should be for the ears and mark it with disappearing ink.

5. The ears can be attached in multiple ways. I sewed the tab on to the hat (facing the back of the hat). Or choose to use hot glue to attach the ears to the hat.

6. Adding the stars & moons to the Sorcerer Mickey hat

Option A - Free hand draw these designs onto Heat n' Bond. Iron the shapes onto white cotton fabric. Cut out on the lines and iron directly onto one of the blue cotton pieces of the hat. Take care not to place the pieces too close to the edges where the hat will be seamed together.

Option B - Draw the designs onto a piece of paper to create a pattern. Using the patterns, cut out the shapes with felt and then hot glue onto the blue cotton. Take care not to place the pieces too close to the edge where the hat will be seamed together.

Putting the Sorcerer Mickey Hat Together

7. Curve the cone into a conical hat shape. At this point you have several options for seaming together.

Option A - Turn the hat inside out and machine sewed down the seam (right sides together). Carefully turn right side out.

Option B (no sew option) - Overlap the hat seam (wrong sides together). Use heavy-duty staples to close the seam shut. Cover the seam with a strip of blue ribbon using hot-glue.

Creating the hat band

8. For the padded hat band, measure the child's head circumference where the hat will be worn. Add 10 inches to this measurement. The band will tighten once the stuffing is added. It's also easier to cut the band down in size than it is to add another piece of fabric.

9. Cut a piece of the blue cotton the length of the head circumference (plus 10") and 6" high.

10. Fold the fabric in half right sides together (so it's now 3" high).

11. Sew the long end of the fabric, creating a tube, using a ½" seam allowance. Do NOT turn the piece right side out - you will be stuffing this tube while it's inside out.

12. Place a safety pin about an inch in from one side, closing off the tube. Stuff the tube with Poly-fil through the opposite end. Use a dowel or chopstick to lightly push the stuffing down. You want the tube lightly padded, but not bursting at the seams.

Completing the Sorcerer Mickey hat

13. When the tube is padded, compare this hat band to the bottom of the cone hat. You may need to remove some of the fill and trim some of the tube fabric if the tube is too long. Once you have the tube an appropriate size to fit the hat, sew the tube ends right sides together, making a circle.

14. Placing right sides together, pin the raw hem of the tube to the outside of the cone hat and baste. Then using a sewing machine zipper foot, sew the hat band tube closely inside the basting line to secure the band to the hat. Trim excess and roll band down. Ta-da!! Your sorcerer's hat is complete!

Mickey and the Roadster Racers Costume

This is a completely handcrafted costume, so it may take a little longer to put together than the other two DIY Mickey Mouse costumes. I have included tips for sewing a complete costume as shown, or for putting together the outfit with ready-made pieces.

If you're not up for sewing something elaborate, this outfit could easily be put together by making it with a few store-bought items. By adding yellow felt designs to a sweatshirt and pants, then applying hand-painted patches, you'll have an inexpensive and unique Mickey Mouse costume!

Creating a Mickey Roadster Racers Costume

Sewing the costume

If sewing the costume, you'll need to be familiar with sewing stretchy fabrics. Using a zig-zag stitch or a Serger is a must, in order for the costume to properly stretch.

• I made this jumpsuit and hood by following this McCall's Costume Pattern. However I made creative adjustments to add the color blocking. Refer to the Disney character image when designing the costume.
• Red spandex or knit stretch fabric (purchase the amount required for the appropriate measurements of the pattern)
• Yellow knit or spandex stretch fabric (about a yard for accents)

Creating the costume with ready-made pieces

• Red sweatshirt
• Red sweatpants
• Red beanie
• Yellow felt, for racing details
• Black felt, for Mouse ears on hat
• White felt, for the "buttons" on front
• White cotton, to use when making the racing patches
• Black and white checkered ribbon, to sew onto the side of each leg
• Fusible bond, like Heat’n Bond Lite Iron-on Adhesive OR Hot Glue Gun
• Fabric paint, like Jacquard Fabric Paint (8 Pack)

Instructions for Mickey's Roadster Racer Costume

When creating the patches for this Roadster Racer Mickey Mouse costume, I use fabric paint and cotton fabric. It is much easier to paint on cotton than directly onto stretchy knit fabric.

I fuse white cotton patches onto the fabric, stitch carefully around the outside, and then paint my design onto the cotton. You can make these patches as detailed or simple as you wish, depending upon your painting abilities!

1. Draw out your patch designs onto white paper or print out clip art found online.

2. Place your printed designs on the window with a piece of tape. Use a Sharpie to outline the outside edge of the design onto the reverse side of the paper. This will create a “mirror image”.

3. Hold a piece of fusible bond (bumpy side down) onto the mirror image (the backside that you just traced). Trace out the outline of each shape using a Sharpie marker (ball point pens or pencils will smudge or smear off onto your iron, so a Sharpie is best).

4. Iron the white cotton fabric to smooth out any wrinkles. Iron the fusible bond pieces (bumpy side down) onto the WRONG side of the fabric.

5. Cut out the patch shapes on the lines.

6. Place the patch shapes (fabric side up) onto your printed design. Use a disappearing ink pen or pencil to lightly draw the details of each patch onto the cotton fabric.

7. Peel off the fusible bond backing. Lay your outfit down and smooth out the fabric. Lay your patch shapes down on the outfit, make sure the design is placed where you want it. Press with a warm iron until each patch is secured.

8. Optional to secure, use a straight stitch to sew with a small hem (¼″) around the edge of the fabric, securing each patch shape to the outfit.

9. Carefully paint each of the patches using the fabric paint. Work carefully not to get paint on the actual outfit (use blue painter tape around the edges to protect fabric, if desired).

This article was originally published October 5, 2017 and has been updated and republished with a new date.

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