Plants vs Zombies Cone Head Zombie Costume
Get ready to rule the backyard battlefield with this DIY Plants vs. Zombies Conehead Zombie costume—complete with a lightweight mask and signature traffic cone!
This Plants vs. Zombies Conehead Zombie costume is so cool! The step-by-step zombie mask instructions are super easy to follow too.
Okay, fellow Halloween lovers, you know I live for spooky season. There’s something magical about the scent of pumpkin spice, the sound of leaves crunching underfoot, and the mad dash to pull together creative kids’ costumes that are both epic and homemade.
Every year, we have a ton of fun coming up with creative costumes and getting into the Halloween spirit. I especially love this time of year because the boys’ birthday is at the end of October!
This year, they were determined to be Plants vs. Zombies characters and celebrate with a Plants vs. Zombies birthday party. No pressure, right?
Too busy to make this right away? Pin it for later! Pin this post to your favorite board on Pinterest and it will be there when you’re ready!
Why You’ll Love This Project
This DIY Conehead Zombie costume is hilariously fun to make, surprisingly light to wear, and doesn’t involve a drop of fake blood. It’s the perfect not-so-scary zombie look for Halloween parties, trick-or-treating, or a Plants vs. Zombies bash.
Plus, no complicated sculpting or messy paper mache in sight! The materials are simple, budget-friendly, and easy to work with, even if you’ve got a couple of curious helpers buzzing around.
Zombie Costume Details
Every fall, the boys challenge me to think creatively. Just when I think that we can’t possibly top last year’s 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. In other years, they have had a Mario & Luigi go-kart costume, Angry Birds costumes, and even Star Wars Angry Bird costumes.
DIY Plants vs. Zombies Conehead Costume
When they asked for Plants vs Zombies this year, I really did try to talk them out of it. I wanted to sell them on easy wins like a black cat, ninja, or ghost, but no dice.
But the boys were determined that this would be the year of Plants vs. Zombies costumes. Cam wanted to become a Chomper Plant and Isaiah insisted on the classic Conehead Zombie.
How could I say no? Obviously, I did what any crafty, sleep-deprived mom would do—I rolled up my sleeves and got to work.
What is a Conehead Zombie?
A Conehead Zombie is one of the classic enemies from the popular video game Plants vs. Zombies. He’s basically your average slow-moving zombie, except that there is a bright orange traffic cone jammed onto his head for extra protection.
That cone actually gives him more defense than a regular zombie, which means it takes more peashooters to knock him down. Conehead Zombie is a fan-favorite for kids and gamers alike!
Honestly, this truly is the perfect zombie costume for a child’s Halloween party. Most zombie costumes are full of fake blood and special effects, but there’s no gruesome gore here!
How to Create a Plants vs. Zombies Zombie Mask
First things first, I wanted to find a building material for the mask that was NOT paper mache. I wanted to avoid it at all costs.
Have you ever worked with paper mache? It’s messy, takes a ton of time to dry, is heavy, and did I mention that it’s messy?
Lucky for you (if you are here to create your own cartoon-like zombie costume), I found a brilliant lightweight, inexpensive, and not so messy material to work with and I’m sharing it with you!
Plants vs. Zombies Conehead Zombie Costume
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Supplies
- 2 Aluminum casserole pans – These become your zombie head. Bonus: they’re super lightweight!
- Duct tape
- Green acrylic paint
- Black acrylic paint
- Paint brush
- 3″ Styrofoam ball
- 2.5″ Styrofoam ball
- 4 1.5″ Styrofoam squares
- 5 Black pipe cleaners
- Scissors
- Glue gun
- Caution cone
Instructions
1. Bend the corners out of the aluminum pans. Cut a 4″ x 2″ mouth hole near the bottom third of one of the pans. Roll back the aluminum to form lips. Tape both pans together to form a hollow zombie head (leave the bottom open).
2. Cover the entire head in duct tape to smooth out all of the bumps and edges. The tape replaces traditional paper mache, adds structure, and smooths everything out.
3. Paint the whole head with green acrylic paint.
4. Cut off one side of each Styrofoam ball to create a flat surface and hot glue them onto the head for eyes. Glue the Styrofoam square teeth into the mouth.
5. Use black paint to add details like eyebrows, outlines, and shadows. Twist and glue pipe cleaners to the head to create wild zombie hair.
6. Glue on the caution cone. Throw on some ragged thrift-store clothes and you’re ready to join the zombie horde.
I think it would be fun to create a zombie bride to make this a couple’s costume. All you would need is a thrifted white dress, a veil, and a little makeup to give you that undead look!
Tips and Tricks
- Use a plastic cone from the dollar store for a lighter and safer option than a real traffic cone.
- Test the mask size before gluing everything so your little zombie has enough breathing room.
- For even more personality, let your kiddo customize the face with silly eyebrows or a lopsided grin.
- Spray seal your paint job with a clear coat to prevent smudging during candy-hunting chaos.
- Add a neck strap inside the head with an elastic band to keep the mask from wiggling around.
- Let the duct tape cure for an hour before painting—it helps the paint stick better and stay vibrant.
A Seriously Awesome Zombie Costume
So, what do you think? Pretty awesome, right? And hey—if you’re feeling the Plants vs. Zombies costume theme, don’t miss Cam’s Chomper Plant costume tutorial too.
The brilliant thing about these costumes is that the masks aren’t heavy or awkward to carry around. They should be comfortable enough to party all night long, and keep the kids warm and dry!
As a fan of the TV show, the Walking Dead, I can’t get enough of zombie Halloween costumes! Paired with a fun zombie walk, this would definitely win a costume contest at any of your Halloween parties.
Frequently Asked Questions
How do I make a Plants vs. Zombies costume at home?
Use lightweight materials like aluminum pans, duct tape, and Styrofoam to build the head. Paint it green and top it with a plastic cone for the signature Conehead Zombie look.
Is this costume good for kids?
Yes! This DIY zombie Halloween costume for kids is non-scary, comfy, and made from soft, safe materials—perfect for school parties and trick-or-treating.
How long does it take to make?
It usually takes about 2–3 hours to complete, depending on how much help (or distraction!) your kids provide during the process.
Can I make a matching Plants vs. Zombies family costume?
Absolutely! Have someone be a Peashooter, Chomper, or even Crazy Dave for a hilarious family group costume.
Where can I find a traffic cone for the costume?
Check dollar stores, toy sections, or online for lightweight plastic cones. Avoid using real ones—they’re heavy and awkward for kids to wear.
If your kiddo rocks a Conehead Zombie costume this Halloween, I’d love to see it! Snap a photo, tag me, and let’s celebrate the creepiest, cutest undead around.
Bonus points if you throw in a zombie walk and a groan that sounds like someone trying to get out of bed before coffee.
If you love this Conehead Zombie costume, please give it a five-star review and share it on Facebook and Pinterest so others can enjoy it too.
Check out even more epic kids’ costumes below!
[mv_create title=”Epic Kid Costumes” key=”34″ type=”list” layout=”hero”]
More Costume Ideas
- DIY Yip Yip Costume
- Muppets Beaker Costume
- Plants Vs Zombies Pea Shooter
- Demogorgon Mask
- Plague Doctor Mask
- Plants Vs Zombie Chomper
- Demodog Costume
- Beetlejuice Costume
- Mario and Luigi Costume
Oh my gosh, this is so totally awesome!!!
I can’t say I’m familiar with Plants vs Zombies, but that is one awesome Halloween costume!!! Reminds me of something you would see in Beetle Juice. You are creating some very special memories for your kids. Pinning this one!
So cute and inexpensive to boot!!
Do you know what the dimensions of the pan were that you used?
9×12 ish :)
is the pan super deep? I have a couple regular pans and I cant imagine how once taped together there will be room for a head in there. The sides measure 2 1/2 inches….
Good question! Yes, the pans are 4-5″ deep. :)
Love it! How did you get the duct tape so smooth I tried and have visible lines everywhere
I used a few layers of duct tape which helped. The lines also added to the “look”. :)
Where did you find the caution cone?? Thanks for the instructions….very helpful….was looking for a way to avoid paper mache and this is the perfect alternative.
Dollar store – have fun!
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.
you saved our halloween. geniuss ideaa thank u a millionn for sharingg
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.
YAY!!
Just made this mask in like an hour! It was awesome! Thank you for sharing! :)
YAY!!! I would love to see a photo :)
Wow, my son and husband are still obsessed with plants vs zombies. This tutorial is awesome as my husband is going to be conehead and I really hated the idea of another year of paper mache. Reading your description I felt like you were talking about me LOL. I love the halloween costume challenges my family throws at me.
Oh yay!! That’s so fun. Crazy the things they come up with they?! I would love to see your finished costumes when you’re done! heatherpainchaud@hotmail.com