Archive for October 21st, 2011

Flap Jacks for Halloween

Well, the title of this post might be a bit misleading…I’m not posting a recipe for flap jacks (or commonly known as pancakes — or cakes of pan in my house!). I am, however, going to share detailed instructions for creating a flap jack costume as my nephew Jack (the fire-maker Thanksgiving Weekend) asked if I could sew him one. Sadly, I have committed to a freelance design project and won’t have the time before I leave, so I created detailed instructions on how to make the costume.

I immediately envisioned this costume in my head, so it was a matter of simply drawing and putting words to it. I tried to keep it as simple as possible, but I wanted a convincing costume so that Jack as Flap Jack would be pretty obvious. Click on the illustrations to see a full size version.

Illustration of Flap Jack Costume


    • 1 1/2”  Thick Foam – enough to make three full circles about 15” above the head to the knees.
    • Glue gun or spray glue (spray glue must be specific for foam)
    • Light beige long sleeve T-shirt, to match pancake.
    • Dark brown leggings and shoes.
    • ORDORLESS Spray paint for foam (Michaels will have this, ordinary spray paint will dissolve the foam):
    • Light beige for pancake,
    • Slightly darker brown for golden cooked parts of the flap jack,
    • Golden brown for syrup
    • Bright yellow for butter.


Cutting a giant circle

  1. To cut the rounds required: Measure about 12-15” above Jack’s head to about his knees.
  2. Divide circumference by 2, and cut a piece of string about 5” longer.
  3. Tie a pen or marker to the string on one side, and a safety pin to the other side. Safety pin it to the centre of the foam.
  4. Holding the string tight, draw a circle around the centre (like a giant compass).
  5. Cut THREE rounds like this. Save the corner pieces (this will be the butter).
  6. On ONE circle, cut an oval for the face about 12-15” from the top of the round.
  7. Place the face hole over Jack’s face and approximate where his arms would need to come out, and cut two smaller ovals for the arms.

Cutting a place for your face and arms

For the syrup:

  1. Place the cut (with face and arm holes) on TOP of one of the remaining circles  and trace where you put the face and arm holes.  Cut them out as close to the original size or SMALLER than the first one.
  2. Now cut the syrup in an amoeba-like shape so that it looks like it was poured and is oozing all over the flap jack.

Syrup Pattern

The butter:

  1. From the corners of the foam, cut a pat of butter in a rectangle form like shown. To make it more 3-D, cut 3 the same shape.
  2. The 4th and top layer of the butter, should be cut to be drippy on two sides, as illustrated.
  3. Assemble the butter layer over layer, so that they are glued together as tightly as possible to each edge, including the one that has the melty drips, allowing the melty drips to stick out (they will be glued to the flap jack on assembly).

Butter is cut from left-over foam. 4 layers gives you the height/thickness needed


  1. Paint the TWO OUTSIDES of the flap jack circles the light brown colour.
  2. Take the slightly darker paint and spray cooking marks on both sides, as illustrated (it doesn’t need to be perfect, cooking flap jacks is not perfect either!)
  3. Spray the syrup the golden darker brown on ONE SIDE.
  4. Paint the butter the bright yellow, even the edges.
  5. Allow all three pieces to dry completely (you may want to put outside so it doesn’t smell too bad).

Painting the pieces


  1. Glue the two main flap jack pieces together so that you ONLY glue 3/4 of the way around, starting from the left outside leg to the right outside leg (this allows Jack to slip into the costume from the bottom. ONLY GLUE THE EDGES.
  2. Glue the Syrup on top of the FRONT LAYER (the one with the holes for the face and arms) making sure you LINE UP the face and arms PERFECTLY).
  3. Glue the butter onto the Flap Jack making sure you don’t cover the face or arm holes, place where ever you want. Glue the melty bits so that it oozes down the side of the butter edges ONTO the flap jack.
  4. Make sure the glue has enough time to dry before you wear it.

Assembly is easier than you think


  1. An electric knife is perfect for cutting thick foam, MAKE SURE MOM OR DAD ASSIST.
  2. Try to get ODOR FREE spray paint and glue. It could be smelly.

Copyright Eva Taylor. You may copy this pattern for your own personal use or on your blog as long as you link back to my blog and give me credit for it.

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