Director Anne Fletcher was thrilled when Katherine Heigl
signed on to her comedy 27 Dresses
(due out Jan. 11)—about a perpetual bridesmaid and her menagerie of tacky wedding gowns—save for one problem. "Katie's got a beautiful body," says Fletcher. "So you put this god-awful thing on her and she makes it look good! It was like, 'What can we do to really make that ugly?'" So she asked Cat Thomas, the film's costume designer, to "find the ugliest thing in every palette." Thanks to Heigl, the job "was a costumer's dream," says Thomas. "She was such a trouper, she would put anything on." Thomas dished on the most memorable dresses, and their on-set nicknames, to PEOPLE's Lesley Messer.
'Weddings are women's biggest fantasy moments, and it's important to have fun with it!' —CAT THOMAS
To see all 27 of Katherine's dresses, go to PEOPLE.COM/27DRESSES