Ah ha! Success is mine finally. I called Simplicity this morning and had to leave a message. They called me back and was not at all helpful. The lady on the phone insisted that the pattern measurements were right and that there should be no puffing. Obviously I had problems, that's why I had to call them. Anyway, I went to bug my neighbor seamstress and she saved the day! She showed me how to trial and error reduce the pattern by laying the original and down on a folded piece of paper and cutting it down. Ultimately after 3 tries, we (she) got it. This is what I had to work with this afternoon:
The rest of the pattern to finish off the project was fairly straight forward. I thought the button holes and buttons would be tricky, but it turned out pretty easy. Here's my finished product:
Although the b-day boy is turning 1, I sized this for 18 months...that way he can grow into it. I didn't want to risk making it too small and being a waste of my effort. I saved my pattern so that I can make one in the future of our little guy : ) Now I'm looking for a hoodie that I can applique one of these Woody cars to the side of. I think it would compliment this nicely. I went to Target yesterday and didn't find anything. Any suggestions?