Plants vs Zombies Costume – Cone Head Zombie

Plants vs Zombies Chomper Zombie Costume DIY Tutorial-038

Oh my gosh you guys!! We are SO EXCITED for Halloween!  Every year we have a ton of fun coming up with creative costumes and getting into the Halloween spirit.  It is an especially awesome time of year because the boys’ birthday is at the end of October too!  This year they were determined to be Plants vs Zombies characters.  Today I am sharing the first of our costumes, this Plants vs Zombies, Cone Head Zombie.

Plants vs Zombies Chomper Zombie Costume DIY Tutorial-040

Every year the boys challenge me to think creatively.  Just when I think that we can’t possibly top last years costumes they ask for the impossible, the complicated, the unique, the character that can’t be found in stores.  I love that they have so much faith in me and think that I can create anything.  But sometimes I very much doubt myself and my ability.  When they asked for Plants vs Zombies this year I honestly tried to talk them out of it.  How about a black cat I asked?  Or a ninja?  A ghost?  Alas, they were determined to become characters from the popular game, Plants vs Zombies.  Cam wanted to become a Chomper Plant and Isaiah, a Zombie.  How could I say no?

In years past they have had a Mario & Luigi Go Kart Costume, Angry Birds Costumes and even Star Wars Angry Bird Costumes.

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So how does one create a cartoon-like zombie costume you might ask?  I wondered that myself and set off to find a building material for the mask that was NOT paper mache.  Have you worked with paper mache?  It’s messy, takes a ton of time to dry, is heavy and did I mention that it’s messy?  Seriously messy.  So I wanted to avoid that at all costs.  Lucky for you (if you are here to create your own cartoon-like zombie costume) I found a brilliant light, inexpensive and not so messy material to work with and I’m sharing it with you!  Here’s how to create your own Plants vs Zombies mask…

Plants vs Zombies Chomper Zombie Costume DIY Tutorial


Two aluminum casserole pans (dollarstore)

Duct tape

Green acrylic paint

Black acrylic paint

Paint brush

3″ styrofoam ball

2.5″ styrofoam ball

Four 1.5″ styrofoam squares

Five black pipe cleaners


Glue gun

Caution Cone

Plants vs Zombies Chomper Zombie Costume DIY Tutorial-001

Step 1: Bend the corners out of the pans.  Cut a hole in the bottom third of one of the pans about 4″ by 2″.  Roll back the aluminum to form “lips” around the mouth.  Tape the two pans together to form a head shape.  Be sure to leave a large hole at the bottom.

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Step 2: Cover the entire project in duct tape to smooth out all of the bumps and edges.  This replaces traditional paper mache method where paper and paste are used to smooth out the surface of a project.

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Step 3:  Paint the entire thing green.

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Step 4: Cut a flat spot into the back of each styrofoam ball.  Hot glue the styrofoam eyes and teeth to the head.

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Step 5: Paint on black details and hot glue pipe cleaners to the head.

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Step 6: Glue on the caution cone.  Add a shabby outfit and your Cone Head Zombie costume is complete!

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Here’s a sneak peek of Cam’s Chomper Plant costume too.  The tutorial for that will be posted next week.  The brilliant thing about these costumes is that the masks are quite light and not heavy or awkward to carry around.  They should be comfortable enough to party all night long… and keep the kids warm… and dry!

Plants vs Zombies DIY Zombie Costume

Do you have costume plans for this Halloween?  If you become a Cone Head Zombie we would love to see your creation and feature it here on the blog!! Please share…

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  1. Kristy Wilhoite says

    Thank you so much for this! I am 99% finished with the zombie head and we are quite pleased with the results. Good directions, inexpensive items…yay! Now to get started on a Jedi robe…sigh. Thanks again! I will try to post a finished project pic.

  2. Angel says

    Wow!!! Thank you. I was scared to make this but of course my son decided he wanted to be PvZ character and so attempted it. It looks good and we got so many compliments. He wanted to be the bucket head one so we stuck a bucket on the zombie instead of cone. Thanks for the super easy diy instructions and make me look like a hero to my little one!!! Much thanks again.


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