Last year I found a penguin costume pattern, Simplicity 3639, and suggested to my husband that we be a family of penguins for Halloween this year. He laughed and said, "No way!" I've tried talking my kids into being penguins for Halloween, but they had other ideas. So when my younger brother asked me to make him a Halloween costume, guess what he got!
It wasn't cheap, even with buying the fleece half off, but still cheaper than buying an adult costume. It's fairly easy to make, and fleece is cinch to work with because you don't have to worry about finishing the seams. It's a great costume for cold-weather locations.