Headless Horseman Costume

Tutorial: Headless Horseman Costume


My husband made his own costume this year, and he has been pretty excited about it…and I must say that he did a pretty darn good job! He let me take pictures of him making it, so I thought I would give you a little tutorial on how to make your own Headless Horseman costume…

Headless Horseman

Step 1: Get a very big box.

Great Big Cardboard Box

Step 2: Cut it out to look like this: (sorry about the free hand arrows…)

Cardboard Cutout

Step 3: Now you need to cut a hole in it that will be extra big for your head to fit through…my husband traced around a big pot =)

Measure your Head

A hole for your head

Step 4: Cut out the hole and bend down the front and back flaps:

Cut out hole

fold down front & back

Step 5: Now you need to make your biceps & if you want too, you can reinforce the folds with duct tape:

make some biceps

Step 6: Try it on for size!

headless horseman

Step 7: The fun stuff begins and you get to add some muscle, use spray foam and build up your shoulders so they will come up to your ears. David built his up about 6 inches.

foam muscles

add foam to build up your biceps and your chest, you need to look big and buff. After it dries (let it dry overnight to make sure it dries all the way through because it does get kind of thick) you can use a knife to shape it so that you don’t have any weird bumps…and please DON’T use a good knife…grrr. =)


Step 8: Get a XXL turtle neck that will fit over your new muscles and big shoulders. (You may want to find one before you begin so you can know about how big you can make yourself…) Then you can make accessories like a vest, scarf, cape etc. Yes, that is my dear husband using my sewing machine. (He ONLY sews costumes…he wanted that to be made VERY clear. ha ha)

David sewing a vest

In order for you to be able to see, you will also need to make some kind of eye holes. We just cut little holes in the seam of the turtleneck and David wore a pair of glasses under the costume so it wouldn’t push so hard on his face and he would be able to see better…

And Voila! You have one awesome Headless Horseman Costume…I’d love to see pictures if any of you make one!

Halloween 2009

Happy Halloween!


  1. That is SO COOL! Thanks so much for sharing the process, I’ll be linking to this.


  2. that is one of the cutest posts I have seen! tell your husband that part about ONLY sewing costumes..is priceless…


  3. Thank-you for sharing this! The costume turned out great! I will try a variation of this this year for my fiance who funnily enough also happens to be named David. LOL Will try to post pictures :-) Thanks again!


  4. The only thing that would’ve made this better than we’re gonna do is if your baby was dressed as his jack-o-lantern head! My dog is gonna be his horse, and I’m gonna be a wench.


  5. This is awesome. Thanks for sharing.


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