While the tutorial itself makes for a child-sized costume, you should be able to make it in any size by sizing up following these same instructions.
Here are the items that you will need:
> Fleece fabric for the bodysuit and hood > Scraps of fabric for eyes, nose, etc. > Fiberfill or fabric scraps for stuffing the ears and tail > 1/4 inch wide elastic > Safety pin > Velcro > 12″ invisible zipper > Thread in main fabric color, white and black > Large tracing paper > One piece pajama and a hooded jacket for the patterns > Hand sewing needle
I broke down Cherie's tutorial into 8 parts to make the process a bit easier.
Part 1: Bodysuit (Steps go with above photos in order)
> Place pajama on tracing paper so that the pajama is aligned with the edge of the paper.
> Trace the outline of the pajama adding a seam allowance (Cherie uses 1cm).
> Move pajama and trace the armhole and necklines free-hand.
> Round the pattern around the hips and thighs to get a better Totoro-shape. Add 3/4″ to the leg bottoms for hemming. Pattern for front piece of bodysuit is now ready.
> Place another tracing paper on top of the front piece (extending the edge by 1/2 inch as seen in the photo). Trace the same front pattern again but raise the neckline in the back to math pajama. Pattern for back piece is now ready and you will cut 2 of these pieces.
Part 2: Sleeves and front details (Steps go with above photos in order)
> Trace the sleeve shape. Add seam allowance and extra 3/4″ for hemming.
> Place another tracing paper over front pattern and draw a circle for the tummy design. You will need to cut the front pattern on the fold, 2 of the back pieces, 2 sleeves cut on the fold and a tummy circle cut on the fold as well.
> Make a 2" wide strip of fabric to finish the neckline and make sure it is a few inches longer than the neckline itself. (Cherie uses a 20" long strip).
> Cut out the chest designs details from the main fabric.
> Pin the arrow designs on the tummy piece and top stitch close to the edge.
> Pin the tummy onto the front piece and top stitch close to the edge.
Part 3: Invisible back zipper (Steps go with above photos in order)
> Open zipper and place it along the straight edge of one of the back pieces. Sew close to the teeth.
> Fold the back along zipper. Sew the center seam together with a 1/2" seam allowance (the while line). Sew beyond the end of the zipper and on the inside of zipper as well. Reinforce by backstitching few times.
Part 4: Shoulder and necline (Steps go with above photos in order)
> Line up shoulder seams of the front and back pieces and pin them. Sew along the shoulder edge leaving a 1cm seam allowance.
> Pin the fabric strip on the raw edges, and sew with a 1cm seam allowance and cut off any extra strip.
> Fold edge of such that the zipper teeth are along the edge. fold the binding over to the opposite side of the body suit so the neckline is enclosed.
> Pin along the neckline and sew the binding down on the inside. Cut out extra fabric.
Part 5: Bodysuit Completion (Steps go with above photos in order)
> Line up the sleeves with the shoulder seam and sew with a 1cm allowance.
> Cut 2 pieces of fleece for the tail. Sew the curved edges together and leave the top open. Flip it inside out and stuff with fabric stuffing. Place it on the bodysuit right below the zipper and sew the tail to the bodysuit.
> Place the front piece on the back piece and sew along the side seams and the inseam.
> Flip it right side out.
> Sew the arm and leg holes. Leave a casing to insert the elastic using the safety pin.
> Bodysuit is READY!
Part 6: Hood (Steps go with above photos in order)
> Trace the hood line of your hooded jacket on the tracing paper, leaving a 1/2" space between the edge of the paper and the edge of the hood. Add a 1cm seam allowance. Draw a straight line 1cm below the edge of the hood.
> Cut 2 hood pieces. Cut a strip of fabric 3 inches wide and a bit over twice the length of the bottom edge.
> Pin the curved edge of the hood and sew with 1cm seam allowance. Fold the hood in half and sew the front edge of the hood.
> Fold fabric strip in half, lengthwise. Sew along the short edges, a centimeter away from the edge. Flip it right side out and poke the corner out.
> Line the edge of the fabric strip with the edge of the hood and pin it along. Attach the band to the hood, such that you only sew one layer of the band.
> Sew along the edge.
> Fold the band right sides together and sew from the edge of the hood around the corner of the band. Clip the corner and then turn right side out.
> Sew velcro to the hood.
Part 7: Hood detailing (Steps go with above photos in order)
> Cut out the eye and nose details out of fleece or felt. Stitch details as close to edge as possible.
> Cut out 4 year pieces. Place two together and sew along the edge. Leave the bottom open and flip it right side out.
> Stuff ears with stuffing.
> Attach the ear to the hood with the hand sewing needle. Tie knots inside the hood.
Part 8: Wear your awesome Totoro costume!