DIY Olaf Hat + runDisney Costume

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Check out our kids’ Olaf costume too!

DIY Olaf hat and runDisney costume from All for the Boys blog

During this years Disney Social Media Moms Celebration we were invited to run a special runDisney fun run through Disneyland, California Adventure and ending up in Carsland. Before it opened. Just for us. It was the best run I’ve ever done. Running through Disneyland when all you could hear was the music from the speakers was so amazing trying to soak up every bit of it was all I could do!


(Photo by Josh Hallett)

I will say that dressing like Olaf will get you a bit of attention 😉 I swear there were a couple kids who would have bought the hat right off of my head if they could! I promised their parents that they could make it so I’m going to show you how to make your own and you DON’T have to be a professional costume designer. I am so very far from it.

Start with a white hat – I bought mine from (affiliate link) Amazon. You can’t go wrong for $6.95! You’ll also need dark grey, black, brown, white and orange felt sheets (find them at any craft store for around $.30 a sheet not on sale) brown pipe cleaners, low temp glue gun, scissors, this free printable and fiberfill stuffing is optional.

DIY Olaf hat and runDisney costume from All for the Boys blog

For the printable open up the PDF with Olaf on it (the first one in the folder) and print at 300% – this is how my printer dialog looked when I printed mine. I used the lowest quality setting. Most printers have a “poster” setting where it will separate the photo onto multiple sheets. Just make sure the eyes/eybrows aren’t broken up.

Screen Shot 2014-05-06 at 11.19.53 AM (1)


DIY Olaf hat and runDisney costume from All for the Boys blog

Now you’re just going to use the print out as the template to cut pieces out of the felt. If nothing else at least copy the eyebrows exactly. Olaf’s eyebrows make him Olaf!

DIY Olaf hat and runDisney costume from All for the Boys blog

DIY Olaf hat and runDisney costume from All for the Boys blog

I used the dark grey for the shadow behind his eyes since I think it helped a bit with the “depth” of his eyes. Don’t forget the light reflection on the pupil (I used a white Sharpie paint marker)

DIY Olaf hat and runDisney costume from All for the Boys blog

For the carrot cut out a triangle so that when rolled the top (largest) part is about 3″ across so around 6/7″ when layed flat.

DIY Olaf hat and runDisney costume from All for the Boys blog

Glue the edge and roll into a carrot.

DIY Olaf hat and runDisney costume from All for the Boys blog

Stuff with fiberfill (confession: mine was stuffed with dog toy stuffing since it was laying all over the floor when I was making mine). and hot glue the end well.

DIY Olaf hat and runDisney costume from All for the Boys blog

Starting with the nose as close to the bill as you can get glue the pieces onto the face of the hat.

DIY Olaf hat and runDisney costume from All for the Boys blog

Don’t foget his teeth!

DIY Olaf hat and runDisney costume from All for the Boys blog

Form hair with pipe cleaners and hot glue around the little button on the top of the hat.

DIY Olaf hat and runDisney costume from All for the Boys blog

My hat is still in perfect condition after the run and drive both ways!

DIY Olaf hat and runDisney costume from All for the Boys blog

For my shirt I cut out his buttons on black felt and stitched them with a few stitches onto a white running shirt the night before. I only did a few stitches so I could take them off and use the shirt by itself later.

Huge thanks to New Balance (who gave us amazing new shoes) and runDisney for sponsoring this fun run!



(Photo by Josh Hallett)


(Photo by Josh Hallett)

There is a reason that runDisney runners have increased 40% from 2012 to 2013. It’s such a supportive and amazing experience for everyone! They have upcoming runs, training and travel information on their site.

Have you ever done a runDisney run? Are you planning to? My son is begging me to do one so we’re looking at our first official run as well!

Disclosure: Our family was invited to the 2014 Disney Social Media Moms Celebration. In exchange for a conference fee, I was provided with room accommodations, park passes, several meals, and admission to conference events. I was not asked to write about our experiences at the conference or about sponsors at the conference. While posting is not a requirement, we had so much fun we just want to share some of the magic with you. 

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Allison Waken is a wife, mom of boys and Phoenix, AZ native. She has been creating inspiring content for All for the Boys since 2011. Allison loves travel, movies and spending as much time as possible with her family while she can!


  1. All for the Boys Reply

    Thanks Wendy! I am definitely not a seamstress so I was very happy with how easy it was to put together!

  2. Hi, the olaf costume is great !!, never done any of these before….how did you glue the carot to the hat as it's much heavier than the other pieces?

  3. All for the Boys Reply

    I hot glued it as well! Just added plenty of glue on the end and I put it as close to the bill of the hat has I could get it so that some of the weight could be held by that. It hasn't come off after the trip to CA, the run and back home being played with by my kids.

    Hope that helps!

  4. I made your Olaf hat for my son (4 years old) for our first trip to Disney World. All day guests and cast members comment on his hat and talk with him as if he was Olaf. He has warmed up to the idea of strangers talking to him and is now offering them warm hugs!
    Thanks for such an amazing tutorial! You have made our vacation even more magical!

    • Oh this just made my day! Thank you for taking the time to comment and let me know. I’m SO glad he liked it and sounds like he was proud to look like Olaf. I bet he was the cutest one there 😉

  5. Thanks for the inspiration. I made the hat for my nephew, I can’t wait to see the look in his face when he sees it.

    You can see a pic of mine on Instagram. My name is POLAROID_KAM

  6. I’m making thus for our spooky 5k! Were the Ann’s costumes made or purchased! I need one for running.

  7. So cute!! I recently shared a maternity rendition of your hat, so thank you so much for the inspiration!! My three year old is so psyched that Mom is going to be Olaf.. now fingers crossed I don’t go into labor before Halloween I’ll have a way harder time embracing my snowman like figure if it’s a post pregnancy bump hahaha

  8. Hi! I found your blog while searching for ways to make a homemade Olaf costume. Yours is AWESOME, so much less expensive to make – and – I like it better! (My stepdaughter is going as Elsa so I wanted an easy costume to wear when I walk her through the neighborhood on Halloween.) THANK YOU SO MUCH for sharing the instructions with all of us! I can hardly wait to see her face when I surprise her with Olaf!

    • I’m so glad you found it! And yes definitely cheaper and easier to find. I bet you all will look SO cute walking around the neighborhood. You’re so welcome!

  9. Thanks so much for posting this amazing DIY project! I made it last night for me to wear this weekend when we take our 3 year old, “Elsa”, to a princess Halloween party. I also made a sign that reads “Hi! I like WARM hugs” to wear around my neck. 🙂 We are taking a family trip to Disney World in Florida in a few months and I’m thinking I’d better find room in the suitcases for this Olaf hat, too! lol

  10. This is great! I’m going to make two so my husband and I can wear it to our daughter’s “Frozen” birthday party. Such and easy idea, yet it looks so fantastic. Thank you for sharing!

  11. Chris Kochenower Reply

    I made some of these hats for my wife, daughter, my daughter’s bitty baby, and myself to get our pictures taken with the Frozen characters on the Disney Wonder. I wore my hat many days while I was wandering around the ship, and I must have gotten around a hundred comments about how much people (crew and passengers alike) liked these hats.

    • I love hearing stories like this! That you so much for taking the time to let you know! I love that you made one for bitty baby too!

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