DIY Sulley Costume from Monster’s Inc.

How to Make a No Sew DIY Sulley Costume from Monster’s Inc.

Mike: Can I borrow your odorant?

Sulley: Yeah, I got, uh, Smelly Garbage or Old Dumpster.

Mike: You got, uh, Low Tide?

Sulley: No.

Mike: How about Wet Dog?

Sulley: Yep. Stink it up.

-Monsters Inc. (2001)

Finally! The last part of our Monsters Inc. family costume DIY’s. Today, I am sharing my 7-year-old daughter’s costume, Sulley. I have already shared:

I DO have to make a disclaimer before I start the tutorial.  I can’t sew. I can, but I can’t. Not clothes, anyway. I’m just intimidated by it and do everything I can not to sew. So, for her blue hoodie, I went to Salvation Army and found this women’s extra small blue one for $6.00 and took a glue gun to it.

I figured this would be ok because she will likely only wear this costume two or three times. And what do you know? It worked!

OK, one more disclaimer. This costume is my interpretation of Sulley.  It’s obviously not a full fuzzy head to toe monster costume, rather a child’s fun Sulley-esque costume that would be perfect for Disneybounding. Here’s how I did it.

Woah woah woah… OK, a THIRD disclaimer. In my materials list I share some recommended products that I use that are affiliate links.  OK no more disclaimers… back to the tutorial.

Check out the video tutorial:


DIY Tulle and Felt Skirt

Time: 20-30 Minutes


  • Purple or Blue Ribbon (2 yards)
  • Purple and Blue Tulle (6”X25 yards)
  • 2 Sheets Purple Felt
  • Scissors
  • Hot Glue and Glue Gun


I have made this skirt many ties including an Alice in Wonderland version and a long Queen of Hearts version. This one is no different.


First, cut the entire roll of tulle in 20” strips.  I used two different colors so I did a half a roll each. One by one fold each strip in half and make a larks head knot around the ribbon waistband.  This will make the length of the skirt just under 10 inches. Make sure you start in the center of the ribbon and make your way out on each side.  When you are finished, the skirt will be about 20” around.  You can slide and maneuver the tulle to make it a little smaller or wider as needed.

Next, cut out purple circles. They don’t need to be perfect.  Hot glue them randomly around the tulle skirt.  I had my daughter put on the skirt while I glued.  The skirt is puffy enough that the warmth of the hot glue will not come close to touching her.  Just be extra careful though!

Thrift Store Hoodie Makeover

Time: About an hour


  • Old Hoodie
  • Half Yard of Fur
  • Fabric Scissors
  • Scissors
  • Paper (to make a pattern)
  • Hot Glue and Glue Gun
  • Tan Felt Scraps
  • Cotton Balls


Using paper, create a pattern for the hood. Cut it out, trace it onto the back of the fur and then cut the fur out. Repeat it on the other side.  Glue the two sides together.  You will now have a fur hood.  Glue the fur hood to the sweatshirt hood. The easiest way is to start on the seam and glue the outer edge only.


Cut fur cuffs to add to the arms.  Since this hoodie was too big for my daughter, I trimmed the arms of the hoodie first. Glue the cuff around the wrist area using hot glue.

To make the horns, I free hand drew horns on tan felt. I cut them out, glued the two sides together, turned it inside out, and then stuffed each horn with cotton balls. I glued the horns onto the fur of her hood.

Sulley’s Claws

Time: 10-15 Minutes



Finally, I had these gloves laying around the house. I decided to use them for this costume.


I cut our pointy nails out of black felt scraps and glued them onto the fingerips.

Here is the after.


I will post a round up of all the Monster Inc family costumes and take pictures of our entire group as soon as I can!  I hope you like this… and just in case, here they are again.

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