I picked up a yard of felt in each color: tan, red, yellow, green. I followed this burger suit tutorial. I cheated with my cardboard and used the base of my papasan chair (rough circumference of 22"). I cut my tan felt for the buns 2" larger and folded around the back of the cardboard. I hot glued around until there was a 6" gap remaining, and stuffed the bun with fiberfill (I used one large size bag of fiberfill).
Next came the cheese triangles on front and back to look like one square slice of cheese, then a couple of red tomatoes. I followed the tutorials recommendation and cut the green large enough to cover the entire surface of the cardboard to give the suit a more finished look.
My husband turned a yellow shirt inside out. We found a pair of jean shorts at a thrift store and red converse at Shoe Carnival. The shoes were the most expensive piece of this costume!
I put this project off the longest because I dread sewing and I've never made a hat. I used this pattern which included a good video tutorial. I needed an adult medium, but I was using felt (which won't stretch), so I cut the felt out to the large size to have a comfortable seam allowance. To give the hat ear flaps, I added two inches to the bottom edge and cut away the face after it was sewn. To get the ears to stand up, I vaguely used this tutorial to wire the ears.
I used 18 gauge wire and molded it to the shape of the ears:
I used masking tape to cover the ends of the wire.
To make the ends of the ear flap, I tapered the ends and glued them together.
This costume worked out amazingly well. I went to the thrift store and found a great green dress to wear and got to wear my super comfy mary janes. I was surprised at how many people enjoyed our costumes and wanted pictures. This was my favorite costume so far.
Thanks, Bob's Burgers, for being awesome!