Homemade Halloween Costume - How To Make A Dinosaur Costume

Home Stager with Sharon Tara Transformations

Homemade Halloween Costume - How To Make A Dinosaur Costume

My three year old grandson, Jack, wants to be a dinosaur for Halloween...not just any dinosaur, Jack wants to be a Spinosaurus.

I looked online for ideas, but all I could find were cutesy dinosaurs... sew some triangles down the back of a hoodie and add a tail to the bottom.  Jack doesn't want to be "cute"... Jack wants to be scary.

I LOVE creating Halloween costumes and was excited to take on the challenge.  A couple of people online suggested using foam to create a dinosaur head...so  I bought a 46 x 70 piece of 1 1/4" foam ( I ended up using about 1/2 of it), got an old bike helmet, and got to work.

I couldn't be happier with the results!!

homemade dinosaur costume

Want to make a dinosaur costume for Halloween?  Here's how I did it....

Dinosaur Head

pattern for foam dinosaur head

Using scissors or a serrated knife, cut out a 16" x 22" piece of foam. 

Round off one end.

Measure down 14" from straight end, and cut a 3" slit on both sides.

Cut two more slits (on rounded end) as shown in picture.


Bending all the pieces and attaching them together forms the top of your dinosaur head.

Start by hand sewing section A to section B.  (A should overlap B)

Next, attach section C to section B.  (C should overlap B)

Next, attach the remaining side sections (D & E) to the rounded section.



Hot glue the top head section to a bike helmet.

top section of dino head


foam dino mouth




Cut out a 9" x 18" piece of foam for bottom of mouth.

Round off corners at one end.

Cut out a 5" x 7" opening at straight end.  (This is where child's neck goes.)

Cut out a 3.5" x 45" piece of foam for side of mouth.

Hand sew the two pieces of foam together.   Side piece should be on outside of mouth piece, not on top of it. 



Hot glue the mouth piece to the top of the head.  This gets a little tricky.  You have to glue it to both the foam and to the helmet.  If you have any glue gun experience at all, you know this is where the cursing begins.   After the bottom was glued on, I made a few tucks (See A & B)  using needle and thread, to give the head a better shape.  I then attached a piece of foam to cover the back.  (C)

making foam dinosaur head

adding details to foam dinosaur head

Time to get really creative and add some detail features.

I added two triangle pieces of foam to shape the eyes and another  longer triangle between the eyes.

I attached spikes running down the back of the head and neck.

I used hot glue to attach all the foam pieces.

You have to press hard and hold in place for a little while for foam to stick to foam.  

Expect more cursing!


As if I hadn't been burned enough yet, I then used the glue gun to cover the entire head with green felt.

I lined the inside of the mouth with brown felt.

I added teeth cut from craft foam....one sheet took care of the whole mouth.


dino head covered with felt

I cut a styrofoam egg in half and hot glued a plastic eyeball to each half.

I used brown and silver fabric paint on the entire costume to create more detail.  

make your own dinosaur head


Dinosaur Tail:

I followed this fabulous "How To Make A Dinosaur Tail" tutorial.

Dinosaur Hands and Feet:

Rather than have Jack wear the dino hands, I chose to make them to sit on top of his hands.  I cut pieces from felt, sewed them together and lightly stuffed.  I attached a piece of elastic to the palm side to fit around Jack's wrist.

dino hands and feet

The dino feet are the same pattern as the hands, just a little bigger.  I added a "cuff" and pieces of velcro to the top of each foot which will wrap around Jack's ankle.  A piece of elastic is attached to the bottom.  (The elastic will be under Jack's shoe and hold the dino foot in place.

I used packing peanuts for claws....cut a point at one end and attached with hot glue.  


The Dinosaur's Body:

My suggestion would be to use a sweatshirt and sweatpants.  I had green felt already glued to the head when I realized I couldn't find green sweats.  I had to improvise.  I found two matching sweatshirts at The Salvation Army.  I used one of the sweatshirts to make the pants.  Honestly, I won't even try to write a tutorial for Jack's dino body because I just sort of pieced it together and made it all work.

I recommend determining your body color (finding sweats) before buying felt for the other parts.  


If you do make your own dinosaur costume, I hope you will come back and share a picture!

Jack love's his costume!!

jack's dinosaur costume


More of My Halloween Costume Ideas:

Thomas The Train Costume

Costumes For Kids

Halloween Costume Ideas

Skeleton In Coffin Costume

Halloween Costumes For Groups

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  1. Evelyn Kennedy 10/28/2012 04:58 PM
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Nan Jester
Exit Real Estate Gallery Jacksonville Beach, FL - Jacksonville Beach, FL
Realtor, Exit Real Estate Gallery

You did a great job with this one. I am sure Jack will be the scariest kid on the block. Congrats

Oct 28, 2012 07:24 AM #38
Mark Montross
Catamount Realty Group - Burlington, VT
Listing and Buyer Specialist

Sharon, what a fantastic Halloween costume. It is so elaborate. I would be sure to take lots of photos!

Oct 28, 2012 07:47 AM #39
Karen Fiddler, Broker/Realtor
HOM Sotheby's Intl Realty, 949-510-2395 - Laguna Beach, CA
Laguna Beach & Lake Arrowhead, CA (949)510-2395

That is incredible...truly! I thought I was the queen of homemade costumes, but I think it's time to give up my crown.

Oct 28, 2012 11:46 AM #40
Chrissy Doremus ~ US Inspect ~
US Inspect - Chantilly, VA
Residential & Commercial Property Inspections

I love the biting the fence pic! Hahhaha--great work!

Oct 28, 2012 12:17 PM #41
Grant Schneider
Performance Development Strategies - Armonk, NY
Your Coach Helping You Create Successful Outcomes

That is a great costume, Sharon.  I am sure that your son will be very proud to wear it.

Oct 28, 2012 01:20 PM #42
Travis "the SOLD man" Parker; Associate Broker
Team Linda Simmons, Enterprise, AL 36330 - Enterprise, AL
email: Travis@theSOLDman.me / cell: 334-494-7846

haaaaaa - AWSOME!! As already mentioned - some type of book, even an eBook, might pay for a few more ideas and trials!!

Oct 28, 2012 03:25 PM #43
Sharon Parisi
Keller Williams Dallas Premier Realty - Dallas, TX
Dallas Homes

Sharon, this is truly the most precious costume I have ever seen! You are so creative!   I used to make my daughter's costumes and it was so much fun!  You have brought back many memories!

Oct 28, 2012 04:39 PM #44
Evelyn Kennedy
Gallagher & Lindsey, Alameda, California - Alameda, CA
Alameda, Real Estate, Alameda, CA


I am so impressed with your creative and sewing ability.  Thanks for the instructions which I may use in the future.

Oct 28, 2012 04:52 PM #45
Sharon Tara
Sharon Tara Transformations - Portsmouth, NH
New Hampshire Home Stager

Roger:  You should see how funny it is in person...when he runs the mouth bounces open and closed like he's chewing.  LOL!

Lanise:  Thank you!

Emilia: Thank you...Happy Halloween!

Nan:  He loves to roar like a dino when he's wearing it....really enjoys scaring people.

Mark:  We have taken lots of photos....a really funny one coming up for Wordless Wednesday this week.

Karen:  The ultimate compliment, thank you!

Chrissy:  That's one of my favorites too!  He did that on his own, so glad we got a picture of it.


Oct 29, 2012 05:27 AM #46
Sharon Tara
Sharon Tara Transformations - Portsmouth, NH
New Hampshire Home Stager

Grant:  Thank you!  It's actually my grandson....and yes, he loves wearing it!  He told me that when he wears the costume "all the other kids are going to want it, but they can't have it because my Neena made it for her boy!"  

Travis:  I'm glad you enjoyed it!

Sharon:  It's been many years since I've made children's costumes...I started up again last year with a Thomas the Train costume for another grandson Zack.  I love the creative process of putting it all together!

Evelyn:  I don't do any real sewing....only rough work like costumes.  The sewing aspect of this was really basic and simple.  Forming the head was the greatest challenge.  I hope if you do make one, you will send me a picture!

Oct 29, 2012 05:35 AM #47
Rob Renk
Carrington Mortgage - McKinney, TX
AE | Carrington Mortgage loans down to 550 FICO

What a wonderful costume.  you surely are talented in creating one so life-like.  Thanks for sharing the how-to.

Oct 29, 2012 06:07 AM #48
Sharon Tara
Sharon Tara Transformations - Portsmouth, NH
New Hampshire Home Stager

Rob:  Thank you!  I couldn't be happier with how it turned out!

Oct 29, 2012 11:44 AM #49
Brad Baylor
ERA Coup Agency - Milton, PA

Sharon - That's a pretty freakin awesome costume!  Great job!

Nov 01, 2012 12:31 PM #50
Sharon Tara
Sharon Tara Transformations - Portsmouth, NH
New Hampshire Home Stager

Brad: Thank you!  He'll be out there trick or treating tonight!

Nov 02, 2012 12:05 PM #51
Karen Steed
Tallapoosa, Bremen, Waco, Buchanan, Temple, Carrollton - Tallapoosa, GA
Associate Broker Haralson Realty licensed in GA and AL

Sharon - You did a wonderful job!!!   I hope your son was thrilled.

Nov 05, 2012 08:19 PM #52
Karen Steed
Tallapoosa, Bremen, Waco, Buchanan, Temple, Carrollton - Tallapoosa, GA
Associate Broker Haralson Realty licensed in GA and AL

I mean grandson...You just look so young

Nov 05, 2012 08:20 PM #53
Sharon Tara
Sharon Tara Transformations - Portsmouth, NH
New Hampshire Home Stager

Karen:  Thank you and thank you even more for the compliment!

Nov 06, 2012 02:15 PM #54
Donna Foerster
Cherry Creek Properties, LLC - Parker, CO
Metro Denver Real Estate Agent

Hi Sharon~ I'm cleaning out my blog bookmarks, but I wanted to keep your instructions so I posted the photo and the link to your post to my Halloween Pinterest board!

Dec 07, 2012 08:10 AM #55

Loved the costume. Made it much to the suprise of my teammates for the Ragnar Northwest Passage Relay this last weekend. :)



Worked amazing :)

Thank you ever so much.

Robb Landis

Jul 22, 2013 04:48 PM #57

Thank you for sharing your directions.  I made a version of your design for my 3.5 year old son for Halloween this year.  It came out great and he LOVED it! I really appreciated having your pictures and instructions to help guide me through the process.  Thanks!


Nov 01, 2013 06:57 PM #58
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Sharon Tara

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