Puchiko is my favorite anime character, ever. Not only is so cute you could fall over, she's extremely witty, and I think she has her head screwed on a bit tighter than Dejiko and Rabi! =P
I made two versions of the entire costume, and at three versions of the hat, until I was totally satisfied. The shirt was made from a nightshirt pattern, because I wanted it to be extra big and fit comfortably. I found a pattern for the sailor flap online, and sewed a ribbon on one side for the stripe, and then sewed the two peices together and ironed it so it would be nice and neat. In my first version of the costume I couldn't figure out how to get the collar to go on right.. then I realized... INTERFACING! So I managed to get the collar perfect this time. The shorts were simple. I didn't have a pattern for those, so I just randomly cut out two giantic leg peices (used a diagram for a reference). I made the waistline and leg holes two times bigger than what it needed to be, and scruneched it up with elastic, for that extra poofy look.
The hat and feet were probably the most involved part of the costume. I found a tutorial on the hat here on the forums, and I modified it (after about three tries) to get it right. For the feet, I wanted to give them the slouchy schoolgirl sock look, so I added elastic in the ankles and also around the top so they'd stay on. Stripes were added with brown felt and heat and bond. I made the whole thing out of a perfect shade of orange fleece! Whee!
The wig is probably my favorite part of the costume. I found a beautiful and perfect wig. It was a high quality one too, which really surprized me because it was only $10 at a costume and dance shop by my house. I angled the front just a bit, and put it into pigtails. I also made antenne which are so prevailant in the series. First I took a small peice of hair from the bangs, wrapped a tiny clear elastic around it, then seperated it and tugged gently to put it in place. Then I sculpted it with glue and styling gel afterwards. It came out great and really made the costume look awesome!
I was told by one of the judges that if we had entered cosplay we would've won judge's choice. But we lost track of time and we forgot to sign up! Eeek! Gonna compete with these at Sugoicon 03. =)