tions.
Original Playboy Bunny outfits do have such blemishes, but they should be avoidable if the
Dissecting A Playboy Bunny Costume
The following article with drawings describes an actual Playboy Bunny costume from one of the
now closed Playboy Bunny Clubs. No affiliation between the authors and any companies or orga-
nizations mentioned in the article is implied or should be inferred. Trademarks mentioned are
owned by their respective companies.
The purpose of this article is to describe in detail the costume being examined. The drawings
given here are based off of an actual Playboy Bunny outfit. The cuff and collar drawings for
example are actual outlines of areal cuff and collar. The satin panel drawings show the shape of
the outside satin layer and can be used to create the inside polyester/cotton blend layer. Details on
the bone casing, bra cups and such things as where stitching was done is included.
The article's use of the word "dissecting" is in reference to carefully analyzing and figuring out
how the outfit is constructed. The stuffing was not knocked out of the tailor bone casings ripped
apart. It is possible to look at the open ends of the bone casings and figure out the materials and
design used. Proto-types have also been made to create a pattern that describes how the tail is
constructed. The information in the article is provided "as is." When possible other collectors
were consulted to check that the design described matches other outfits.
Materials
The materials used in making the Playboy Bunny outfit include a satin that might be a polynosic
fiber -- a newer type of rayon that can handle exposure to water. But this has not been proven yet
although a thick rayon satin has been the closest match so far. The inner lining appears to be a
35% polyester and 65% cotton standard weave white cloth. The stiffener used in the ears is a type
of interface mesh material standard weave with about 28 threads per inch and the bias cut finer
mesh used to sew the ears to the stiffener is about 40 threads an inch. The bone casings include a
thick nylon. So far no exact match has been found for the Satin or nylon, but close equivalents
can be found at most fabric stores including the grommets and shoe laces.
,
The boning is a 7/16" spiral metal boning that can still be purchased today. One store www.far-
thingales.on.ca has had this type of boning in stock. Bra cups that are made from a tricot covered
foam similar to the original material can be found as item numbers 2851000 to 2853000 at
www.stretch-and-sew.com under notions section.
Construction
An aspect of construction should be noted. The satin layer has to be made 118" wider than the
inner lining. If that extra material is not added, the seams between the panels may be pulled too
much for the satin and will result in a blemished surface around some of the seams. The blemish
will typically be 1/8" wide and will stop there if the satin has not been damaged too badly. The
poly/cotton material can easily take the stress, but the satin surface gets ruined under such condi-
outfit is fitted and constructed correctly.
For unknown reasons, those constructing the outfit attached the outside layer to the inside layer by
sewing directly on the surface of the satin. This is mentioned in the drawings and is often men-
tioned along with reference to a blue colored thread. The outfit this article is based on is blue and
so any mention of a blue thread is because it matches the outside satin color.
It is possible using a 5/8" allowance instead of the 1/4" allowance used in the actual costume, to
attach the layers by sewing only on the allowances hidden on the inside. The original outfits
appear to only have done this for the center front seam. It also appears that for the original outfits
relied on the exira 118" added to the satin to create enough bulk around the panel-to-panel seams
enough to hide the externally visible stitches.
Further note, only the first costume had the external sewn attachment.
Other costumes did the satin to liner attach on the inside.
Alternate Sewing Design
In this article the panels are numbered from I to 8 starting with the panel to the right ofthe zipper.
It is possible to combine panels 4 and 5 (the two front most panels) into one panel just for the
inner lining. For appearance reasons the satin should be cut with 4 and 5 as separate. Using two
layers instead of one, the bone casings can be made much easier by simply sewing a channel sand-
wiched between two poly/cotton layers. This technique requires that the.allowancebe atleast 5/8" p
and two layers be attached by sewing to the left and the right of each seam forming a channel for
a bone. Twill tape could be added to add opacity but the poly/cotton material is strong enough by
itself.
-ftlsousingaJlextra-)loly/c-ottol1layer under the satin for the outer layer couldbe optionally added
to add further strength. Below is a cross section of the altemate design that can be used at each
boned seam:
Please feel free to ask questions. With feedback more detail could be added if something is not
clear.
PANEL 4 and 5 TOP OUTSIDE VIEW

"~
Add 114"allowance on sides
Add at1east5/8" around leg holes End cap appears here even though
zigzag stitoh 112"lower
Note no zigzag stitoh Note boning can move around in this
particular boning case.
End cap
;{"
~s here- A _ Blue stitch through 11••• allowance only Two white thread passes ~

11" Bone
~
.•-. ~ -.-=
~ __.- . 0: •."",-",~~-_ " =-=--==-=-- -----1..:--:---=.:::--:::-- 1

~ Note that boni ng is off center by 1/8"

Bone case edge

on inside
tii
~

83/4" Bone

~"i~"""'-~~-~-'" - -~
Blue thread stitch someIirnes lliewable
I Added 1/8" to wldtl1 of satin panels cause bulky fold around
~~. seams hiding external sewing. Also prevents stress on satin.
~'-...:.
~ Boning edge sewn 10 lining

~
Add 1/4" allowance
lIB" o.-er from boning edge blue thread Is sawn through to front.

Panel3 Panel ••

~f ~throUghbonecaslng
\'TWO white side-by-side stitchings

Blue stitch going through all layers

 PANEL 4 and 5 BOTTOM OUTSIDE VIEW

Note no aeoond zigzag

Blue stitch aft the way down to bottom of panel
/. Blue sewn right over bone casing edge

/ I s-
- - - - - - --::- - - - __ - 1/ •••••• -. •• __ A __ ••••• __

~
-

114" allowance lliewabl .- -

e underbrlght Ught
- - ,- - - - - - - - =--=-~-::-='=-:-=-I- - -
~
---'---J
- • - - - - - -

------------------------
..=::.::.- ••----:;;/-"0
Blue thread

.;;_-..;. ••:::,:=
-':.;.-::r:-~_ ,/
--
A/"
.-~-
Blue stitch
PANEL 3 and 6 TOP OUTSIDE VIEW

/"""-"" .•.
Bone casing wMe thread two passes
Blue stitch through boning and outside satin
318" of backatltchlng here. StItch then continues
down beyond bone casing to endof panel.

-------
9"Bone I

~. Satin bias cover

~Underwlre

~. ~
~ Slze 3 loop placed outside
II" Bone for roselle nama tag.

--------- \ ••• - •• no •••• -"'.- •••• ,~ 1 _

 J
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tv
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a
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WAIST
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-!!!
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a~

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,
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PANEL 2 and 7 TOP OUTSIDE VIEW

---------------- .----.._._--

\ / .>:
~ Pinking cutting inbetween \ ~ EXIra allowance fi

--..
\ /'" ----:: .... -""" ., . .•...
Add 2" and fold over last 1/4"tp protect"_

!ii
~ 5" long dart upto 1/4" wide ~

-="'--=- - - - -
I

,
_c~~j- _.-.CO '.' " ---.
. ...,."'z' .,-::----
-'-'
- --t -...~ ,,,.,,_~
f
Bioe stitch
 I
I

J I
z I
p! I
1'1)

!
Q.
....•
m
~
~
o
~
6
m
<
~
PANEL 1 and 8 TOP OUTSIDE VIEW

'-------_ __ __ .. ..... -.,---

t --"
. ... ...-.-.~__ ...1...-.--_ __ .

\
\------- 1-- ~
lr-=-7-C~~---.-----~"'""-
Boo
ecaalng hidden on Inside -j . - . .u __~·

\ ZIgzag st1tchgoes Ihrough ._ ••_ •. _ •• _. • i ,-- 'f~

_L.

1 112"
••• - and ll••• ' • - - '

!j

....-z... \ Right sick! of zipper shows ~ Size 3 Nickel plate loop

1" extra material
folded behind
zipper
f
1
 0l0=l
.,;
:2
.. "
~
•.
~
s8. ..,.::
N

:c
.9- .8
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.•
s ..,.::••
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& :..
~
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Iu~
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;am :2
.•.•
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e
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DETAILS OF BRA CUP AND BONING

314"wide folded over bias strip (blue poly satin)

Panel 5 to penel 6 se••••

Hand stitching with double blue thread

Two half moon lining material cloth sewn wrong

sides together across top. inverted and sewn
Blue straight stitch to be behind underwlre casing.
not seen on ou1side

~ 1 112" wide folded over

bias strip of blue poly satin
Slightly darker blue than satin.

\
~
\ ~.
Center boning end cap
\
Two passes:
\ 1) connect underwlre case
\ 2) connect to ling Two whfte stitch penes
,\ One blue stitch pass to attach 10 ou1side.
\ l,-v Sometimes blue stitch visible on Outside.
'.\
\
\
/t
~.,..
\
\
Blue stitch sewn through bone casing and allowances 01 11nlngand satin
\
\
\ Ii
Important that boning end behind underwlre
\
\
:1 otherwise odd feeling flexible area results
II
\ 'I Note skip hare In slICOOdpass
1" length of blue thread I
1
\
connects caae to lining ,
II

I I~ Blue stHch sewn through satin. lining and casing

continues down to very bottom of panel
Note possible misalignment of bias strips
between panels 2&3 and 6&7. Front half of
1/4" machine back IIttch outfi t has separate bt as str; p from front.
One outfit. did not have a bias strip on front.
 FLAT VIEW OF 340 THREE PIECE FOAM CUP

INSIDE VIEW

CEi'ITER
LEFT

----:2.- Twill tapa wraps edge before satin and satin poly
bias strip ara folded over and hand sewn 10
attach.
TwlUTape Path

~.~
Twill (80ft poly matertal) goes from top
of boning left, across cen1er to boning on
rIlIllt. Note 'boning' n01 underwlra.

PI!
Tricot (wMe) cOYenedfoam
 STEP ONE BIAS STRIP
STEP TWO

DETAILS ON ZIPPER r: PbIy Satin

I , I _......-- Inner Lining

1-11nch---j
Handsewbia
to Inner IInl~
~EL 7 TO PANEL 8 SEAM
Panel 7 to panel 8 seam
PANEL 7
Two Viewable
OUTSIDE .~ il / "- ~ 12 per Inch)
Bias to panel 8 per Inch blue thread It-- -T;;-';'ughstitch
Straight zipper,
(b~7nlng and satin. Straight StllchM
going through satin. lining
./ and zipper.
1 Inch ~~ ~ti_~~~ ~p ~ II '
I " II
! Ij
Contused hand stitch double thread. II
Blue thread attaches blao 10 Inner , ~I
,I Note center 01
lining. Not seeable from outalde.

.. .r-tz.- Zigzag 14 per Inch

PANEL 7
OUTSIDE II .A/ Off-" to attach boning
"I'

,
II
I
zipper 114'
off center.
(Sometimes 318")

_n
",- - tIIIIMIifn88 vIeWable " 'I
Brass Hook
to zipper \ \,VV'f'IV'lI! I . Wh~e Ihread all else blue ",.
,. II
t- I~ II
I It I Costume folded back
·1
It \/V to show Intemor.
Two straight IIltch I
I 12 per Inch going ;1
I through satin to zipper.
,I
HIdden knot of
quad thread.
"'1--'" PANEL S (Inslda) PANEL 8
OUSIDEVIEW
Straight stitch

\
Done twice 7 per Inch.
Neither boning seems
attach to aatln.

Two straight PANELS Straight stitch only

)
tIiIch going OUTSIDE on penel 8. but goes
through zipper, through both halves

,,,,,,,,,.,
"nlng and satin
,,/ Th•••• stitchlngs thlCalgh •• IIIyerw
of zipper under
panelS.

~~ ~ Satin
(i _ i9§0: ~ PoIy~ Uning
PANEL 1
OUTSIDE
lWo other straight stitch \ ~Ipper ~Bone CMing
through only zipper and
Inside foldad over part of
satin and lining.
(Rather quickly done.)
T{f~
Zipper \
ZIpper Teeth
TOP VIEW OF LAYERS

SpIral 71te- Metal Boning (CI'Olll MCtion)

(4 '--- 01 bi88 aIrlps)

(Quad thread refers to four threada ruMlng IOgeIher) 1

Quad thread going through loop In metal spiral bone PANEl5 I PANEL 4' {-Fold Seam
and upper surface of bone casing.
Firat four hand stitches are 114' apart The rest at the
9 112" length 01 hand stitching varies as dislance
Increases to 314' uplo " apart. Stops with knot tied
In zipper material.
 DETAILS ON ZIPPER

Short biuB stitching through

outside satin to zipper but not nvlon

I~-
zipper guard,

N:~~I~~ etrIp unfolds a bit --- PANEL 2

OUTSI,DE
Not through
bias
Blue stftchlng goes ail the way through,
Note odd path to avoid metal zipper end,

,-- '-
nylon ~-'
Semi,randOB bUt stiIt:hIngs PANEL 2
,..~~.,- i through nylon onty, OUTSIDE
\
,,~~

Satin poly I"

bias strip
-2. ~ir!~,;;;L--z , '-'1-' - - - - 1'1
Zigzag 3116" wide
14 per Inch
PANEL 1
Ii I' OUTSIDE
I, I whfte lhreed
I I
;7 -:2- Blue thread through nylon only
Hand stitch
double thread
IK:
I",
I ' ""
,"'- :I
" -- -- Metal zipper end unpainted

_____
'''7. -I ' I I I
~- 5112 per Inch
whne thraad through
, --.
I J--
Satin ~' - I 'I I I'
nylon only :I Blue thread only through nyton 9 per Inch
III
Finished side axpoeedti'
--
./?
:
I ,
I i I '.,
1_
I -t-' - ,~
, ....- Random
passes .
left to right diagonal machine

SatlntOllnlng5t1h , ,
I

I
,<,
II ~'1 . 3 layer nyton guard
I,, - "--c !.r~
l'A"-...-
6,5 per Inch (blue)
ii
)'
. ,
I
,I, '
(whne nylon cut on bias)
1314"wlde
I I _' _ ,- -: II Two stra.lght stitch down to the end of

Straight edge CUll!

I i
I I
.
1 l~wh1te
1
I
I
! ~
<blue
:f
i
Zipper guard stretches in
plaCB8to 1 71ff' wide
because of bias cut
I
I
k(

I
<, _
~"zlpper,
I"
Stitches go through outside
satin but not through mylon guard,

0/ satin and lining I I

, ,White thread 5 112"per Inch
INSIDE PANEL 1 />'" Blue Stitlt*lg
Blue thread 9 per Inch
./I~jl't//
'I~
PANEL 1 I PANEL 8
I

~--:r-"·
INSIDE I
1 INSIDE
I.
I
~! I
__

I;

Y.1/'1~l1/'rLl+-'tF
Folded over satin 01panel 8
lining also fOlded Oller and hidden
under satin,

'i OutsIde axpoeed blue sti!chlng

Ends of zl'pper stri'ps
~ Center !old.,.,11 1 to panel 8 seam
 Inside
~ l:r---.---------.-.---~' -Z- 4' wide strip

DETAILS ON BONE CASINGS AND ZIPPER GUARD /lfv"'?;i\!l<W'~ 'Z- ,,. •••••••
Zigzag stitch 3/16" wide

Outside Zipper guard same nylon as bone casings.

No stllfner used. Just nylon .

. ~V"r1/.,:~1
I i"n"p i
-t..l· '.J', , I
1'% ----""I
4-J/~' -'1
I~ ..- jV. i~

Ir-~ 51,"-1i Inside top Is a double loIded I' bias strip

L
with one side cut off to match width of casing.
\ Two passes of straight white stitching. One pass
~ Sometimes a Iwililape Is used. Both types of
I connects bone casing together. Second pass
~o '{J boning may appear In the same outfit
connects to IinIng.
~ --,-_. Nylon
j

1
. .• . .. Ends done Iwlce '~
Ill\["'f1i~l'\'\T""'-: with zigZags I" apart.
I~~.'
'.I."~-,-.'.".""r""
.... , - -. .. - "--. .
Zigzag goos through to lining. Inalde bottom
- Ie nylon. EXAMPLE CROSS SECnONS
Spiral 7/16' Bone OF BONING
SPIRAL 7/16" BONING

~ ••...••.ExampieCut
E· -;::=1

~--z,. To cut, snip twice

[Y'iF 1/8' odd accidental fold

~~~
(
((" ""\

Spiral 7/18' Boning Cap

for covering cUi ends

~UU
Use Iwo needle nose plielS. Pinch

y;,>® At Same Time ...•-uc:=;?

Pinch

P~h
•
f
Pinch
GROMMETS AND COAT HANGER LOOP

Shoe laces are 25" long.

All slftchlno blue thread 10 per Inch. Panel 4 and 5 oulside edge folds over on the Inside

q?--
and sewn under bias strip. Fold provides a surface
for attaching a loop of soft twill tape that can be
INSIDE GROMMET VIEW used to hang outf~ on a hanger.

PlnklngCut
WAIST -'---- _ '-'. _.. ",...,... Satin and lining folded OII8r

,". . ./"
~ and sewn 10hold
_,-
/ •• ' \' 71" '
/ '\ \ II~ I

( It-
I ,I
'I \..
\
iI
I ~ ©! ;'... Do nol put Cinching at... on
grommet section. lIB delign
only allows for decoration.

Note In8CCIJrateplacement ~I©II

I
I1 -
Random back and forth sewing paths to hold tape
to Inside flap.

'. 1\ 'S:J it;;:: .'_...0:= ....

._ '--' ,~. .~, Satin Bias matching outside 811in material

/
.r" . ('i.
~ , .~
. (Not the same poly saUn ueed on top.)
Fold aver edge 1/4' 8I1d sew to hold

)
Sew to hofd fold
~ ~
.rV
,
Sew to outline
grommetaectlon
Sewn on Inside attaching satin and lining
satin and lining together.

Pinking CulB

~"')..Grommet Panel to panel seam

Grommets not accurately poetioned (4 to3 and5106)
CROSS SECTION VIEW Have rough crimped edge on outside to
prevent from ripping tighl&.

Twill Is a soft cotton tape loop 10" long and 112" wide.
ATTACHING FOUR PANELS AT BOTTOM INSIDE VIEW

Hand stitch to fining

~. Blue bias strip

(Same mate,lal as satin)
I
I
I Visible blue Sl~ch outlining
I zlppe,
I.. _

PANEL 1 Blue Satin

PANELS
OUTSIDE
OUTSIDE

~ Blue stitch visible on outside surface

This Is sewn 011&' folded satin.

Blue stitching sometimes visible

• attaching lining 10sstin.
\
PANEL 5 PANEL 4 ---z- Have 318" minimum allowance
on both sides.
~ WhHe lining showing

1) SHieh satin to li~l~

2) SUtch to lining just off fold

/'
~ 4) Attadl bias strip, fold ova, and hand SrM to lining
DETAILS ON BUNNY EARS AND HEADBAND

Half of Headband Cover

-'----------------._-.....",
12 gauge white cotton covered .,.~-....,7,.,:;.S>-----~ ""'1
.> -·-,,-,,--~.....
craft wire

, 5/16" Allowance
I
I

Glued on top
Sew wrong sides together
I
I

leaving 4 1/2' slip knot

opening.
I

Punch two 1/1 S" holes /z,. Side view plastic head band 6"
In 8atln for elastic. -~
Ulcethose for Clear plastic COWlrad with alliin
cheap papsr party
hats,

Slip knot to close

4112' long ">. ""[",'"

2 1/ •.
Punched hole for "
/ 1 1/2' long elastic
o
~
12 l/e'loog head band
Note another pair of ears had
holes for elastic centered l' apart, 1/16" thle!<
~
The diagram above shows an actual pair 01 I' wide
ears where the holes were aCCidentally off
center,
DETAILS ON EARS

,~,
. <f------ 4" ~"1

, Sew lining to wire by wrapping

" In a meshbias s~,
.,'

/'
/

!
\
ANGLED VIr£W SHOWING
EAR FOLD

8"
Final ear shape and peth 01 12 gauge cotton wire

Cut Inner mesh allffnar to ouIiSlde

I shapesize minus.IIow_
cut 31/4" along center tcId.
and

Sew fold 1 to fold 2, I"!, Cut

Pull 10 overiap
(No_Ing)
~
I •..
,----:_ ..••
_•...• ",

Three Stallle$
 OUTLINE OF BUNNY COLLAR

r::=lincw

« ---,------------
Two layers of 35/65 poly/cotton standard weave
wMe cloth are used. No stllfner or fusing.

..--
-~--- .---- ._------
... --------._------ _ .._--_._----- , --."

- - -- /

Stltch done on wrong

sides facing out ..
Collar then turned

I: INSIDE VIEW
Inside out.

Note allowance Is not

very evenlv cut,

_ .._ ....
I
I

~~~-- - - -------1
----, -. -
':"'".;.
.

-,:?
'-,."?j
,..~

BullonS on

(\;f :·'\.-:i
1 ~ \,.-- )\ other aide
',~±)
/I
=---
In this view.
- _ _ _ _ _~_:_::_=--:..--- - ~ - ._=
~ I 1\; \ .. iii- - - _ _ _ _
f : I

/ ....
·t: 1_1 .1 '~... - Flberlnclolhactuallyindicalesthat
-- .•.•. - "( 1;:'~ ~~e there is ~ atraight

8~tch on outside bottom section

- "'\ Sullon Holes this bottom curve Is in the design.
ofoollar.

Inshort bottom portion not sewn

with wrong sides facing out,
 OUTLINE OF BUNNY CUFF

..-.,
. ..,. '-' .~ '---'-----.- "
···v Add 1/2"allowanca
~'
/ .-1 " \\ _ -------_.- -------
,
Sew IwO together leaving slip knot
opan. Turn inside out and close.
/ \ Add button holes.
/ ~Inalde allowance visible wHh light
/'- Allowance cut to 118'
f
I
I

\ I ! I-~_ __ I
1/2' allowance Is cutto lf8'
\
\ around ends where buIIon holes are
\ located.
\
\
\
\ I
\ -'
1:=1 ~IICI1----I I
\
\ ,. ,
\
I I
I
I
Material matches lining of su~.
35/65 poly/cotton cloth
standard weave.

1=-1 I --] \ Button stHchlng 314' long. Hole

cut to 9/16".

~sllPKnot

~
Slip knot Is actually machine sawn on surface
at 12 per Inch. Back stitch 2 stitches.
DETAILS ON BUNNY TAIL
---t--- ----
____..
/
I .r-:
. /
/

/
./
Tail when mulled has a 18 112" perimeter_
Weighs 3 ounces.

/'

----z. Add a 318" aHowanc!l.

\
.••...... ,
~"' I
<, -~,~.-..
.

DART ~ _----.
l. ••.•
_ •..-

..,.....

,/
\ "

f
i
/ "-"'-".
'-..
Sew Darll together, cut extra material oR and
do Ihe same for other two darts,

Whon a "har with lur Inside is Iormed, sew 10 bottom

portion of to edge. Invert through slip knot hole.
s
~
to'

Slip Knot Hole

DETAILS ON BUNNY TAIL

Tall has 1'18' average width to bottom fur ring.

Fur has 3IS'long pile and Is Wh~9w~h a meet base _rial.

Tall has a .ricollike material. Using 35165 poly cotton will

help prevenl hooks from ripping off 100 easily.

Add 31S'allowance oulside

and snip Inside allowance every
Inch and SI1W to base. Add hooks
and sew 10 top.

-: 'JIP:' allowance already added

~
~~ Hook pos~lonlng
Size 3 nickel plaled.

v v\.

_----/
....