DIY Family Muppets Halloween Costumes

We had so much fun making and wearing these DIY family Muppets Halloween Costumes. It took some creative juices flowing, but we found fun solutions for each muppet character.

If you love family costumes, I bet you’d enjoy seeing this round up of 15 other creative family costumes.

Note: This post was originally written in 2012. It has been updated and republished in 2020.

DIY Family Muppets Halloween Costumes

I enjoy going all out on costumes. I’ve done it since I was a kid. I remember in my early years making myself a boom box, jack in the box, Hershey bar – just to name a few.

I guess some things don’t change – even when you become an adult. This year, as a family, we decided to be the Muppets.

The kids had never seen the Muppets, but they liked the idea when we showed them pictures of the characters. We have rented a couple Muppet Movies and watched some YouTube clips to expose them a bit more.

They are all sold out now. Here are the costumes and a brief description of how we did it.

My husband was Beaker. We took some tag board and used spray adhesive to attach the pink felt. Then, we cut a rounded, open slit for the mouth.

How to Make a Muppets Beaker Costume

We put black fabric that he could see out of but shielded his face. For the hair, orange fur was attached to the top with hot glue.

We then turned the tag board into a cylinder by using duct tape and hot glue. A paper plate was glued inside the head tube to create stability.

Next, we took an egg shaped foam piece that we painted orange and hot glued above the mouth opening. We hot glued the foam balls, cut flat, and added black paper eyeballs.

Finally, we cut out notches out of the sides for my husbands shoulders.

The clothes consisted of a business shirt, slacks, tie and lab coat. He also had pink gloves.

How to Make a Muppets Bunsen Costume

I was Dr. Bunsen, and he was the most challenging to make. The only way I saw Dr. Bunsen made by others was with paper mache. I don’t know why I didn’t want to do paper mache, but I didn’t. So, I came up with the idea to make the head out of a Chinese lantern. 

I had a 24 inch Chinese lantern. The inside wire would be used as a brace for my head, so I planned accordingly, reinforcing the area I wanted to cut out for my head with white duct tape. Next, I cut out a hole big enough for my head to go through.

The next part was the most challenging part – working the green felt around the head.

I started the fabric where the front of my neck would go. I did a couple folds around where the mouth and chin would go. Half of a foam ball was stuck under the fabric for a chin.

I used duct tape to attach the fabric in the cut out area and folded a couple duct tape pieces in circles to attach the fabric to the lantern.

A piece of cardboard under the fabric was used for the ears, and I put a clear, small rubber band around them to hold the fabric in place.

I worked and pulled the fabric and gathered as needed until I reached all the way around the back of the head.

The fabric was then inside and taped down. The back of the head wasn’t perfectly flat, but I was OK with that.

I cut out a hole for the mouth and added the black fabric that you can see through.

We popped out the lens and spray painted clown glasses black and attached them with hot glue.

The nose is a half of a foam ball covered in fabric and then goes up to the bridge of the nose.

The clothes were a business shirt, slacks, tie and lab coat. I had big green gloves too.

How to Make a Muppets Miss Piggy Costume

My oldest was Miss Piggy. She wore a pink glamour dress similar to this one (but the one I linked to is way cuter).

She was accessorized with a pig nose, tail and ears, pink shoes and pink princess gloves.

How to Make a Muppets Animal Costume

Kenzie was Animal, and this was definitely my favorite.

I couldn’t find orange tights, believe it or not, so we stuck with red ones. That said, I found some orange tights ones for you on Amazon!

I found some black sport shorts at Goodwill that I cut zig zag around the knee area.

Goodwill provided my long sleeve orange shirt, but here’s one from Amazon that would work.

The vest is two t-shirts (red and yellow). The yellow shirt I just cut short and straight down the center to make the vest. The red t-shirt I just used as fabric that I cut into flame looking things. I finished it off with some sequin trim.

Kenzie’s head was easier than it looks, and it was kind of amazing. We came up with the idea to attach faux pink fur to a bike helmet. The bike helmet had venting areas with a mesh fabric. We just pinned it on there.

Hot glue around the brim of the helmet, and don’t worry, it peeled off easily in the end.

Once the hair was on, we added the foam eyeballs and painted orange foam nose. We used a hot glue gun to attach those.  She had drumsticks and a neck chain as an accessory. 

How to Make a Muppets Animal Costume

Little man was Kermit, and we just bought a Kermit costume. Here’s another Kermit costume for sale at Amazon.

Hoping you enjoyed these DIY Family Muppets Halloween Costumes. We certainly enjoyed creating them and then wearing them to our church harvest carnival.

All the best as you set out to create your own masterpieces in the costume world.