Today’s post for Mario Month is a really fast and easy DIY for making Mario, Luigi, Wario or Waluigi’s iconic mustaches. You can also adapt the same technique to make any other style of costume/cosplay/dress up mustache you’d like.
You will need:
- felt in your desired color
- sewing thread that matches your felt
- sewing needle
- elastic – I used white elastic I had on hand but if you can find elastic that matches your skin tone that would be even better!
- Optional: glue gun & glue sticks
The first thing you’ll want to do is find a reference image of the look you’re going for. I found this clear picture showing all 4 character’s faces from straight-on.
You can freehand your desired shape onto scrap paper if you like. In my case, I cropped out the mustache portion of each image, scaled it for an adult-sized head (with the same proportions as on the characters) and printed it out.
Once you have your template drawn or printed, cut it out and trace it onto your cardstock. This will be sandwiched between two layers of felt to give the mustache stability. For Mario and Luigi it’s not as important, but Wario’s and Waluigi’s need a stronger construction to keep them from falling flat and limp.
Next, trace your template again, this time onto your felt (image 1, below).
Important- you want to cut out your shape BIGGER than the template (image 2, below). You can freehand this when cutting or trace around your outline and then cut along that new line.
Trace the felt cutout a second time (image 3, above). Then stack your two pieces of felt to be sure they are identical, trimming or adjusting if necessary (image 4, above).
Place your first felt piece with the front (public) side facing down. Place your template on top. Make sure your second felt piece is oriented correctly and then sew the middle of a strip of elastic to the center. The ends will be knotted and trimmed later, though if you prefer you can cut yours to length now and sew the two ends together here for an unbroken loop.
Using the same thread color as your felt, sew the two halves of the mustache together with the piece of cardstock in between. You can use a running stitch, backstitch or whip-stitch the edges. Alternatively, you could hot-glue the two layers together.
The two larger mustaches (Wario and Waluigi) need a bit of extra support to remain upright and angled as in the reference images. (You can see how it pulls away from the face on the right side of the upper image). Try on the mustache and mark the spot where the elastic and mustache should meet (as I am doing on the left side of the upper image). Note: it is important to mark these points while WEARING the accessory due to the elastic’s stretch. Once your spots are marked, sew the inner felt piece to the elastic on each side of center.
Here you can see the final Wario result! The two ends are standing up perfectly and the extra two stitches keep the mustache conformed to the face instead of free-floating. They also help hide the elastic when the accessory is viewed from the front.
The process is exactly the same for the remaining characters.
Here you can see all 4. Wario and Waluigi have the extra stitches on the elastic. Mario and Luigi do not and I think they would have benefited from it.
In all, this was a really quick and easy add-on to these costumes. They held up through 6 full performances and many rehearsals, including rushed quick-changes between numbers.
Here’s the full 2022 Mario Month summary:
- Super Mario Bros Warp Pipe set piece
- Mario, Luigi, Wario & Waluigi Easy DIY felt hats
- Mario, Luigi, Wario & Waluigi Easy DIY costume mustaches (this post)
- Wario full costume DIY
- Super Mario Bros bricks stage runner