MOMMYHOOD: How to Make your kid a Sonic the Hedgehog Costume!

My daughter surprised me with a doozy this Halloween-with wanting to be Sonic the Hedgehog. After searching the Internet for a pre-made costume, I opted to make one. There is no real instruction online on how to make one, so I decided to post how I did it, in case there is someone out there who doesn't know and has a Sonic lover in their home too.

Now, I do sew, and the approach I am suggesting means having to sew a basic pattern on a sewing machine with some hand sewing as well. If you can't sew, perhaps you can find some bright blue pajamas or a sweat suit, and cut/glue the rest of the pieces together. The other thing I did buy pre-made online is the above fleece Sonic hat on eBay. Amazon also sells it. If you can't find it, use a "jester" hat pattern as a base and cut felt to match Sonic's eyes and nose, and glue it all on there.

I started with the above McCall's pattern and used the bunny one as a base, but I used bright blue fleece to make the jumpsuit, with a light brown color for the arm pieces and the tummy. The tummy is not in the pattern, you need to eyeball cutting a half moon shape out of each front panel with the brown, and use a brown zipper in that area to match. I made a Velcro tab on a blue fleece rectangular piece at the top of the jumper to keep the top shut and match the blue on the top. The instructions with the pattern are pretty easy to follow for the jumpsuit.

Next, Sonic has big, fluffy "socks" that I quickly made without using any pattern. I just cut two identical rectangles about a foot in width, and 6 inches high. I stitched the ends together to make a "ring, and did a 1/2 inch seam on top and bottom to thread some elastic through. The elastic creates the fluffy sock look and gets pulled on over the jumpsuit by the ankles and stays put.

Next, using the splats in the pattern package, I created Sonic's red gym shoes. I cut 4, 2 inch strips of white about 8 inches long and glued them (using strong fabric glue) on all of the splat pieces (4 total). I sewed the pattern pieces as directed once the glue dried. Then, using gold puffy paint, I "drew" Sonic's square buckles on the outer side of each splat. Then I hand stitched elastic on the bottom edge of the splats so it bridges across the width of the bottom of a shoe and stays put. Following the pattern directions, the splats also have elastic in the top seam over the ankle.

Finally, I hand stitched a pair of gloves with white fleece, and took a sharpie marker to draw three lines over the "knuckles" of the glove. I also eyeballed a sonic "back" (see below) which I stitched together like I would a pillow, and filled it with some poly-fill. I was going to stitch a bottom to this piece, and then put snaps on it as well as snaps on the back of the jumpsuit so that the costume could really be true to SONIC with his spiked back. But my daughter thought the back piece cumbersome, even with the snaps, so I did not finish it. But using snaps might allow your child to take it off or on if its getting in the way of fun!

Below is a quick shot of the finished ensemble! Hopefully, next year, my daughter either learns to sew or wants to be something simpler! HA!


  1. you are AWESOME! This idea is brilliant because my son is OBSESSED with Sonic and he has been wanting a costume for over a year now. I went to the fabric store bought your pattern along with all of the fleece fabric and now i will attempt to make this for his halloween costume this year from your idea. Thank you for sharing!!!!!
    Krystle Aguirre
    San Diego, Ca

  2. Thank you Krystle! My daughter is obsessed with him as well-and I don't know why Sega does not license him beyond the games. I have had such trouble getting her things for her party themes, and of course a Halloween costume! The great thing about this costume here is that it is way warm and comfortable for trick or treating.She still wears it for dress up-even last weekend! A year later!

  3. That is fantastic!!! My nephew is Sonic "obsessed" as well, and my sister doesn't sew. So it's my job to make the costume. You did a great job, hope mine looks half as good!

  4. Thanks Anonymous! Just take your time and follow the instructions on the pattern, its all there and you can do it. The tough part is the zipper, so I would suggest go to some online sewing sites and get advice on how to do the zipper. I suggest also to pin things and baste before running thru the machine. It may take more time on the upfront but faster under the machine! Good luck!

  5. After 3 trips to the costume shop(s) my son FINALLY decided he wanted to be Sonic for Halloween this year. SWEET. Toys-R-Us sells the costume online so it's done... Until you get home and REALLY search to find it is OUT OF STOCK on every, and I mean EVERY, site!!! :( I have no desire to disappoint my son so your how-to is a life saver!
    This is bar far the coolest thing I found when it came to google searching "sonic costume" unless I wanted to pay over $90 for one from eBay and pray it came on time!!! I so appreciate you sharing this how-to and have already comissioned my mom to help!
    Thank you a million times for helping make not only your daughters, but obviously many others Halloween so special for their kids!!!
    -Barbara, Waterford MI

  6. I agree with Barbara!! I have been searching for a week now and just decided to go a head and see if I could make one... you my friend, are a Mother-Saver!

  7. Welcome and thank you for your kind words and feedback, Ladies! I have been getting such traffic on this post it is amazing that this costume is not more readily available for purchase. It seems there is such a need out there!

    I have been thinking of you all and I wanted to mention, if sewing is not up your alley or you really are running out of time, you can probably use some cheap footie pajamas that are royal blue, and go from there. Use the PJS as your base, and hot glue a brown felt circle to the front? And you can still make splats with felt or fleece, using a simple stich or hot glue. Still make a pillow-like back and use snaps to attach it to the back. You can purchase big white mittens for the gloves. I think it can be done without sewing, if that is easier.

    Just some other ideas to help! Please stop by again, soon! Happy Halloween!

    :) UDD

  8. Like a lot of other moms apparently, I searched and searched for costume ideas for a sonic costume. My son wanted to be Shaggy for months before Halloween. Then, about a week ahead of Halloween he changed his mind and said he wanted to be Sonic! Well, there goes my easy costume, where all I really needed was some light brown corduroy pants and a hippie shirt with a vest and maybe a band for around the head. I decided I would try to make it. Plenty of people were discouraging because of such a time constraint but I went and got a pattern (I used one for a fleece one piece zip up pj without feet in them) and got my fabric and was up all night one night and worked all day on Halloween but I pulled it off! Thank you for your post as it did encourage me that it was possible. Although I'm super tired and somewhat sore was so worth it to see my sons reaction to the costume I made. He loved it! Thanks again.

  9. WOW Kerrie! You, my dear, need a nap today! And your son needs to share some peanut butter cups from his candy stash with you FOR SURE. You deserve it! Thanks for stopping by and so glad my post helped and Halloween was a success. My daughter still squeezes into her Sonic costume for pretend play even now. It's "cozy" she tells me. I was up this year sewing an "asian warrior dragon" costume which I will post for others too. I told her Mamma needs a break from sewing next year! We'll see. :)

  10. Can someone make a guide on how to make one of these except like a mascot kinda costume?

  11. I would think a mascot costume would be awesome..but you would need stronger material, especially for the head shape. You may need a foam head to start and carve out the inside of it , and cover it with flet or paint. Or even paper mache head with a wire base to build it off of? And bigger white gloves that you can sew directly to the jumper and polyfill them so they are big and poofy. Same with the feet, but in red.

    Mascots are all about presence, so things need to be sturdier and bigger. Thats all I got! A mascot is a tall order! Hope those ideas help? Thanks for stopping by.

  12. Oh mah goddess, this is so helpful! I can finally make the sonic hat, gloves, socks and shoes i need for sonic boom next week!


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