Heidi Klum Teases Her Epic Halloween Costume and the 'Rough Patch' She Hit While Designing It (Exclusive)

"Things were going wrong, things were not working out," she tells PEOPLE of her latest spooky season sensation

Heidi Klum's latest Halloween costume has had her seriously stressed.

While chatting with PEOPLE on the red carpet at Tuesday's live taping of America's Got Talent, the supermodel, 50, shared that the design process for her latest spooky season sensation has hit a few snags.

"I have had a really hard time. Things were going wrong, things were not working out," she says, even joking that she worried she would end up living out her own "Emperor Has No Clothes" moment.

The costume complications had her ready to bail on the party altogether. "I was like, maybe I just don't come at all and you pretend I'm there because I was already like, oh my God, this is not working out," she says of skipping her own annual Halloween bash. "I have no plan B, so I can't come. I have to call in sick that day."

"Oh man, no, it's been like that. It's been going good, then it's going terrible," she continues. "And then I'm like, okay, I see a glimpse of hope this might work. Then it's not working again. So it's been a rough patch."

Fortunately, her Halloween plans are back on track and her costume idea is coming together. "Now I'm positive again. It's going to work," Klum declares.

Related: Heidi Klum's Halloween Costumes Over the Years

After previously saying her husband, musician Tom Kaulitz, would not be donning a costume this year, Klum revealed that he is now going to be part of her Halloween hoopla. "Yes, he's going to dress up now," she teases, adding, "It is a little bit mandatory in my family."

Klum said Kaultiz, 34, is a good sport when it comes to going along with her over-the-top Halloween costume schemes. "My husband is very good, I have to say. Just being there with me, for me, with all of the shenanigans, because I take it up a notch on Halloween," she says.

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Indeed, every Halloween, Klum somehow manages to epically top what she did the year before. For the dress-up holiday last year, she shocked her guests by slithering into her party in an incredibly realistic worm costume detailed with ridges and a long tail.

Related: Heidi Klum Dances in a Bikini — and Filter of Her Viral Halloween Costume — in Steamy Hot Tub Clips 

The former Victoria's Secret angel's body was completely covered, apart from her eyes and mouth. Kaulitz was her perfect sidekick dressed as a fisherman with a bloody eye.

In years past, the Making the Cut host has dressed up as an alien zombie creature, Princess Fiona from Shrek, Jessica Rabbit, a butterfly and a werewolf. Despite having to cancel her annual party amid the pandemic in 2020 and 2021, Klum still got into the Halloween spirit both years. In 2021, she created and published a short horror film in which she played a zombie mom — and a fashionable one at that — who rose from the dead.

At her 2022 party, Klum told PEOPLE she starts working on her next costume not long after her guests bid goodbye and all the party detritus is cleared away. "Tomorrow," she said, referring to Nov. 1. "When I wake up tomorrow, I start thinking of the next [costume]."

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