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Easy Devo Hat (Energy Dome) DIY

I’ve been sitting on this post for a while but seeing as today is Devo Day I think it’s the perfect time to finally share this really easy DIY on how you can make one of their signature hats.

This is Devo:

Many years ago The Becket Players used the song “Whip It” in one of our shows, and the director at the time had asked if I could make hats for the band and performers. I said “Sure!” because I can make anything. I had no idea how I would make them but I figured it couldn’t be THAT hard, and worst case I could find an online tutorial.

Well. Turns out that in 2015 there were no online tutorials. I believe I’d found one for vacu-forming my own which was not an option. I tested out SO MANY ideas, from cardboard to foam inserts. I tried stacking foam disks and wreath rings… I bought a huge sheet of pink insulation foam to try cutting and carving the shape… nothing was working out. Whatever option I found had to be inexpensive to make, had to be sturdy enough to last through numerous performances, tech week and rehearsals including being tossed around after quick changes, and finally it had to be feasible for me to make TEN of them in a short timespan.

In the end I came up with a method that is both cheap AND easy, durable, and will work great for any occasion where you want to dress up like the Akron rockers.

The only materials you will need to buy are sheets of red Bristol Board and clear packing tape. That’s it! I bought both supplies at my local Dollarama making this VERY cost-effective for the non-profit. You will also need a pencil, a ruler, a pair of scissors, a craft blade, and either a compass or 4 round household items to trace for your circles.

While doing my initial research I’d found someone’s old post providing measurements they’d taken from a vacu-formed Energy Dome they’d caught at a Devo concert. According to that post the actual hat has a 9 3/8″ diameter base that tapers to 8 5/8″, the 3rd ring starts at 7 1/2″ and tapers to 7″, the 2nd ring is 5 5/8″ and tapers to 5 1/4″, and the top ring is 3 3/4″ at the base and tapers up to 3 1/2″. The lower two rings were each 1 3/4″ tall, the 2nd ring is 1 1/4″ tall and the top ring was only 3/4″ tall.

I didn’t want to go to the trouble of making tapered rings as no one would be noticing that closely from the audience.

I found 4 round household objects that fell within similar dimensions as the original hat. My plastic lid was 4″ in diameter, the coaster was 5 1/2″ across, the cheese plate was 7 1/2″ across and the top of my bowl (I traced it top-down) was 9″ in diameter.

NOTE: I’m apologizing in advance for the quality of the images in this post. At the time all I’d had was an old iPhone and didn’t realize the glare off the sheet of laminate I was using as a table-protector was creating a massive glare that blew out all of the photos. I did my best to edit them and make them usable.

Trace out your largest circle as many times as per the number of hats you need. I needed 10 but as this was for a theatrical production I made 11 so we’d have one extra in case of emergency. I was able to fit 5 hats per sheet of Bristol board.

Evenly center your other circles within the first one and trace them all out so you end up with 4 concentric rings.

This next step is optional but if you skip it then for best results you will need to do all of your assembly from the inside of the hat, which can get unwieldly.

To be able to work from both sides, as well as to protect the hat from water and tearing, evenly cover your Bristol board with packing tape. It’s difficult to see in this image but for the ring in the center of the board I only taped across the ring itself and didn’t waste tape covering the two sides that wouldn’t be used. If you want your hat fully water-resistant then you can cover the reverse side as well.

Cut out each of your disks of rings.

Next I marked out strips of Bristol board at the widths I listed for the heights of the tiers, above. In total I needed strips that were 3/4″ wide, 1 1/4″ wide, and double the amount of strips that were 1 3/4″ wide.

After protecting these sheets with packing tape too, I used a craft blade and straight edge to cut the sheets into strips. You can also use scissors if you prefer.

I kept the extra lengths of 1 3/4″ strips as I would need to attach them together to get long enough lengths to go around the circumference of the larger circles.

Use a craft blade to cut the disks into 3 rings and a center circle.

Use packing tape to secure one of the 3/4″ strips around the edge of the circle. This is where the magic of the packing tape happens – when sticking tape to the tape-covered surface the new pieces are nearly invisible!

Use more tape to secure the first ring around the base of the top tier. I did not cover the reverse sides of my board so you can see here how obvious the tape is against the plain paper.

Next, attach a 1 1/4″ strip around the edge of the ring to create the 2nd tier.

This is how it will look after that step is complete.

Repeat the process, moving down layer by layer, and using packing tape to attach everything.

This is the inside of the hat.

Here’s the finished result! From a distance no one can tell that it doesn’t taper the same way as the original, and any tiny gaps or seams where the paper doesn’t abut is practically invisible.

Here are all 11 hats. Once I figured out how to do it they were SO fast and easy to make, and the visual payoff has a ton of impact.

Here they are in-show. All 6 band members are wearing them, as well as the 4 dancers in front. The dancers had some moves where they bent forwards so for their hats I stapled a length of elastic band to the inside, to keep the hat secured. Over the full run of rehearsals and shows we had only one elastic band come loose and no broken or torn hats. In fact, some of the cast members have let me know in the last year that they still have their hats and they’re still in great shape!

They also stack really well for transport and storage.


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Super Mario Bros Petey Piranha DIY

Mario Month 2023’s third DIY is a tutorial for a costume/cosplay for Petey Piranha,

This fabulous fellah is Petey Piranha. He made his debut in Super Mario Sunshine and is confirmed to be the leader of the Piranha Plants. While he’s not as common a Mario villain as Bowser or some of the others, our skit had eight dancers and needed a fourth “bad guy” to oppose our four “good guys”. I’ve already shown how we made the costumes and props for Mario, Luigi, Toad and Peach, as well as Wario and Waluigi. We already had a Bowser, and so Petey here made a great final baddie for our little cast.

I started this costume challenge with a visit to our local thrift shop where I was really lucky and found a solid green hoodie to be the basis of the top, as well as a white skirt as bottoms for our female Petey player.

The first thing I did was to mark off circles on the hood to be Petey’s…uh… face spots…? Mouth dots? I’m going to go with “face”. I used an appropriately-sized candle as a template and traced it out with a white colored pencil. It’s difficult to see in the first image (left side) but I also used a regular pencil to loosely mark off a border around the hood opening.

I used a measuring tape to loosely eyeball how high Petey’s yellow petals should be, based on the proportions of the character. I sketched half of the petal shape on a folded piece of scrap paper and trimmed it out until I had a nice, even petal shape of the right size for my hoodie.

The leftover yellow felt from my Wario costume DIY was perfect for Petey’s petals, and so I used my paper template to trace out 24 halves (to make a total of 12 petals)

I used sewing pins to tack two pieces together so they wouldn’t shift around and then with a regular needle and sewing thread I worked a tiny running stitch all around the sides and rounded top of the petal, leaving the flat bottom unsewn.

You can see in the image (below left) how the petal will look once it is turned inside out. Happy with the results, I continued until all 12 petals were stitched.

I turned them inside out and set them aside.

From there it was time to work on Petey’s face. I didn’t have any fabric paint so used regular acrylic paint for this DIY. I didn’t want the paint to bleed through the hoodie so I prepped it by stuffing it with a plastic bag, which in turn was stuffed with assorted packing materials. This also had the benefit of filling out the hood so I had a flat surface to work on. I also protected as much of the rest of the hoodie as I could by wrapping it in an additional plastic bag.

Using red paint I filled in the entire hood surface EXCEPT for those dots I’d traced earlier, and the lip area I’d marked off. The first image is the result after one coat. The second image was after a second coat of red and also after painting the face spots with white.

A cardboard box worked great as a support to hold the hood in a way that wouldn’t disturb the paint as it dried.

While I had the red paint out I drybrushed a bit around the edges of each petal. To drybrush simply dab off most of the paint onto a paper towel or other scrap surface before working on the felt. This will allow you to get the faded color around the inner edge and give the illusion of a blend.

Continuing to work with the red paint, I set to work on the skirt. After tracing out the spots with the same candle as for the face I painted the rest of the skirt, leaving the spots white. This would have been easier had I found a red skirt – I’d only have had to paint white spots. As it goes with thrift shops, however, you get what you get. (“…and you don’t get upset” as my kids’ daycare used to say!)

The final touch for the petals was to use a tiny bit of brown paint and a very thin, very dry paintbrush and give the centers their subtle center shading.

Before leaving things to dry I gave the skirt a second coat of red paint. I noticed the paint was bleeding into the white spot areas (as shown in the bottom center spot on the left) and so I went over each spot with white paint for a more crisp edge.

Once the paint had fully dried I was able to do the final touches. Petey has distinctive lip stripes, similar to those on a watermelon. Instead of doing detail shading with paint I went the easy route and drew stripes with an alcohol marker.

I used more of the yellow sewing thread to sew each petal into place around the hood. Instead of pressing the petals flat and sewing the one edge down I actually whipstitched the full oval of each petal opening down into the hoodie. This kept the petals open ensured they wouldn’t flop around on stage. Remember – just like all the other Mario-themed costumes and props, this outfit had to be durable enough to endure two weeks of quick-change performances, plus dress and tech rehearsals.

The final step to complete Petey’s face was to add his fangs. After figuring out a paper template to give me a rounded cone shape I traced a small paint bottle enough times for each fang and cut the pieces out from white felt scraps. Each circle was then cut into the flat shape that would fold into a cone.

The cones were then sewn into place around the hood opening. Petey’s fangs are actually more inset into his lips but I wanted to be sure the fangs would be visible from the audience so moved them outwards a touch.

Here’s the final costume.

And here it is next to Petey himself. I wasn’t quite sure in the beginning how I’d pull this one off, but in the end he made a great villain in our little dance number and the costume held up throughout without any issues.

Other Mario-themed projects you might like:

This post may contain affiliate links. This means I might make a small commission on purchases made through the links, at no cost to you.


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Super Mario Bros Toad Hat (Head) DIY

For my second post in this year’s Mario Month I’m going to demonstrate an easy DIY for Toad’s hat. I know – it’s been officially confirmed by Nintendo that it’s actually Toad’s HEAD and not a hat…but most people still refer to the white and red bulb as his hat so I’ll be calling it such in this post.

This is Toad:

A costume for a Toad is pretty simple as almost any colored vest, white pants and dark shoes will get the gist across. The main feature of all Toads and Toadettes is their big, pouffy toadstool-esque hat. Whether you call it a head or a hat there’s no doubt that it’s a needed part of any Toad cosplay and here’s how you can make your own!

What you will need:

NOTE: As with the rest of my Mario costumes & props this hat was needed for a stage show which meant it had to be durable enough to last for a number of rehearsals, dress rehearsals and then stage performances. As such while you can use cardboard to do these first few steps I chose to use plastic canvas for extra strength. The plastic might bend but it would be unlikely to tear or break making it more reliable for quick changes where the hat would get tossed around backstage.

The hat needs structure to support its height so I started by aligning two sheets of plastic canvas vertically and whipstitching the side edges together. I repeated this with a third sheet and then tested the fit around my own head as the wearer would be another adult. I marked the appropriate row, cut away the excess and then whipstitched the final seam to create a tube.

I measured the diameter of the tube and traced out a circle of a matching size on a fourth sheet of plastic canvas, then cut it out. I could have whipstitched around the edge here as well but didn’t want to risk mis-aligning the pieces so for an easier option I used some of the white yarn to tie the disk to the tube in one spot with a knot. I then made another knot directly opposite the first so the disk was centered. I then knotted at the halfway point of each side so the quarters were each tied in place. This ensured the circle was evenly placed on top of the tube. Then I continued, knotting in pairs on opposite sides, until the disk was fully attached.

Try on the hat at this point. The tube will sink down so the disk rests on top of the wearer’s head. For the best result the lower edge should fall just above the wearer’s eyebrows, so if your tube is too long trim the bottom edge accordingly.

For the white outer shell of the hat measure the height up one side of your tube, across the top disk, and then down the other side. Add 2 inches for a generous seam allowance (1″ on either side). This will give you the diameter of the circle you will need to cut from your fabric. I didn’t trust myself to freehand an even circle so I divided this measurement by 2 to get the radius and tied a pencil and sewing pin the radius’ length apart on a length of yarn. I pinned the pin into the center of my fabric and swung the pencil around, keeping the yarn taut, to trace out the shape.

I cut a length of white sewing thread about 1.5 times as long as the outer perimeter of my circle and then sewed a running stitch all the way around, about 1/2″ in from the edge. When I got back to the beginning of the circle I snugged up the ends doing my best to keep the gathers even all around.

I inserted the plastic canvas tube into the bonnet-like white fabric and stuffed all around the sides. Don’t forget to stuff below the tube too so the top of the hat gets its round, puffy shape.

To join the fabric to the plastic canvas tube I switched to white yarn for strength and stitched around the open edge of the tube, through the white fabric. It’s a good idea to keep checking the look of the hat as you go, adjusting the gathers or adding more stuffing if necessary.

Here’s the finished puffy tube. I could probably have added more stuffing but I’d ran out.

Toad’s hat has 5 colored spots. I found a bowl that was a good size for the appropriate scale and traced it out 5 times on some red felt. You can sew the spots in place if you like but I chose to hot glue them instead.

Voila! Your very own Toad hat/head.

The hat can be worn as-is or you can add a chin elastic if needed to secure it in place on the wearer.

It fit our Toad cast member perfectly and just like all the other props and costume parts, lasted through all rehearsals and performances without any signs of wear or damage.

Even through vigorous dance routines and quick changes between numbers!

Other Mario-themed projects you might like:

This post may contain affiliate links. This means I might make a small commission on purchases made through the links, at no cost to you.


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Super Mario Bros Princess Peach Star Wand DIY

Can you believe it’s March already? It’s the 2nd annual Mario Month here on the blog and this year’s first post of the Super-Mario-themed collection is a DIY for a star wand you can carry as part of a Princess Peach costume.

I’d been asked to make the accessories for a Mario Bros skit and was given the above example of the desired wand for our Princess Peach character. Easy-peasy! Most of the needed supplies can be found at the dollar store or you might even have them on hand already.

You’ll need:

Other supplies that I used for the plastic canvas insert step but are not necessary if you use heavy cardstock and/or don’t need your wand to last as long as we did:

Start by scaling an image of the Starman to the proper size for your wand and cut it out of regular paper. (Alternatively you can draw a star shape freehand but I ALWAYS mess those up!). If using heavy cardstock for your star you can jump to the next step. My bag was the perfect color but a bit flimsy, and this prop had to last for at least 6 shows and a dozen or so rehearsals, so I chose to reinforce mine with plastic canvas inserts. If you would like to do the same trace your star template onto plastic canvas. It’s a good idea to mark which direction is “up” so your stars will be sure to align.

NOTE: I should have made my plastic canvas inserts SMALLER than the Starman template. As you’ll see below, I ended up trimming them down so the yellow stars could meet evenly at the edges. To avoid this mistake trace a second line about 1/4″ inside your original edge and cut out on that line.

Wrap your dowel evenly with yellow electrical tape. You can paint the dowel yellow instead but for our purposes the electrical tape was more durable and waterproof. It also allowed me to even out areas where the bamboo was uneven by wrapping more (or less) in those spots. Then wrap again with the silver ribbon, spacing out the wraps to create diagonal stripes. You can secure the ends with regular scotch tape or more of the yellow electrical tape – neither end will be visible once the wand is complete so use whatever you’d like.

Cover the bottom end of the dowel with black tape. I used my fist as a rough guide for how long I wanted the handgrip to be and then wrapped more black tape, padding out the bottom edge slightly for a comfortable hold.

Optional: I debated hot-gluing the plastic canvas to the dowel but was worried it would break or separate during rehearsals (we were a rowdy bunch lol) so needed something permanent and secure. I decided to use the holes in the plastic canvas to my advantage and sew through the dowel to keep it in place. I marked holes on the dowel using the plastic canvas as a template for placement and then drilled directly through the bamboo dowel with my Dremel. I have a Dremel drill press which makes this step super easy but it’s 100% NOT necessary.

Now it’s time to trace your Starman template onto your yellow paper/cardstock.

I used carbon paper to trace onto both pieces at once to be sure both stars would be the identical size/shape, but this is totally optional. Just be sure to trace on the reverse side so in case you leave any pencil showing it will be on the inside of your finished star. I tested the plastic canvas inserts and realized I hadn’t left any clearance so had to trim down both of my stars to ensure the paper pieces would be able to touch. As mentioned above – if you do this be sure to cut your plastic stars smaller to start.

To attach the stars to the dowel I sandwiched them on either side of the bamboo and sewed a running stitch from one side to the other, then up to the next hole, and back to the first side…repeating this until I’d worked through all the holes. I was able to fit my yellow yarn but you can use doubled thread if your yarn is too thick. This will work best if you pre-mark your hole locations onto both pieces of plastic canvas first, to ensure you’ve sewn both stars to the same height and equally centered.

Use yarn to whipstitch the edges of the star closed.

I used the carbon paper again to trace Starman’s eyes and then colored them in with black Sharpie and a white POSCA paint marker.

Cut out both sides of your Starman. As one final layer of stage/rehearsal protection I sealed the paper’s surface with a layer of clear packing tape on both sides. This would ensure that the paper couldn’t accidentally rip or tear.

The final step is to sandwich the yellow star layers on either side of the plastic insert. Place the face side (with the eyes) in front of you and lay a few strips of packing tape evenly across, leaving a few inches of extra tape all around. Carefully pick up the taped piece and turn it over so the sticky side is facing up. Put the wand/plastic piece in place and then lay the back of the star down, yellow-side out, being very careful to line up both stars perfectly. Apply more strips of packing tape so the sticky sides meet and lock the stars together. **It’s a bit awkward to keep the back star aligned while laying the strips of tape which is why I do the face side first.

If not using a plastic insert then before placing the second side use extra packing tape to tape the dowel to the inside of the first side.

Press the tape together really well all along the edges of the star to really seal the front and back together, and then cut around the star leaving a thin strip of taped edge. It won’t show much (especially from the stage) but it guarantees you don’t trim too close to the paper and create a gap between the pieces.

Enjoy your star wand!

Ours worked great – lasting well through all rehearsals, tech week, and performances!

Other Mario-themed projects you might like:

This post may contain affiliate links. This means I might make a small commission on purchases made through the links, at no cost to you.


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Annual Halloween Roundup

It’s October, so that means it’s time for my annual roundup of costume-related patterns and tutorials available here on the blog.

Here’s a step-by-step tutorial on how to make Minecraft Steve & Creeper heads.

Next up (with over 420,000 impressions on Pinterest in the last 60 days alone!) is a similar tutorial, this time for making a Minecraft Enderman head along with a diamond block trick-or-treat box.

Both projects include full charts for game-accurate colors and the exact hex codes for perfect color matching!

If your idea of fantasy is less block-based and more magical, here’s a free knitting pattern for an easy scarf in the Gryffindor house colors.

If training a dragon is more your thing, here’s how to make a viking vest.

If you prefer Pokemon to Night Furies, here’s an easy, last-minute Pikachu costume idea.

If your friends-group themed costume runs more Grease than Greninja, here’s how you can make a super simple Poodle skirt.

If you’re looking to visually upgrade some inexpensive props, here’s a demo on repainting plastic swords.

If you’ve got a last-minute party invite to deal with, here’s a SUPER quick ‘n easy Jughead Jones (from Archie Comics) costume tutorial with free burger dream bubble printable!

If your group costume needs accessories, here’s a free tutorial on making Super Mario Bros Mario, Luigi, Wario and Waluigi hats

If you want to take those Mario Bros costumes one step further, here are instructions on making their respective mustaches

If you REALLY want to go all out, here’s the full costume breakdown with instructions on making an entire Wario costume

Finally, if you’ve got enough knitting time on your hands, you can knit my Baby’s First Superhero Costume pattern as-is with cute designs for boys and girls, or convert the chart and the colors to create your superhero of choice.

Find more tips and tutorials on my How-To page!


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How To: DIY Super Mario Bros Wario Costume

All month long I’ve been sharing Super Mario Bros-themed DIYs for my official 2022 Mario Month, and today’s post pulls all the Wario costume pieces together with some final touches to round out an easy DIY Wario costume.

For a refresher, here’s the yellow-and-purple guy himself:

And here’s how my cosplay turned out:

You will need:

To make the Wario hat you can follow my DIY instructions here.

My easy DIY instructions for the Wario mustache are posted here.

Wario’s gloves are a pair of simple white gloves with a rolled cuff and large blue “W”s on the back of each hand. I used an inexpensive pair of winter “one-size-fits-all” stretchy gloves and the same dark blue felt as for the W on his hat.

Because my costume was needed for several performances with quick (and rough) costume changes, I sewed the “W”s into place with matching thread. If you’re not worried about durability you can choose to use hot glue instead. In both cases, however, I would attach the letter while wearing the glove, as if you sewed it while laying flat it would not stretch properly once worn. (The glue or stitches would hinder the gloves’ stretch and the letters would appear wonky and/or possibly detach).

Repeat the process for the other hand.

Note: I’m right-handed, so it was easy to sew the left glove while wearing it, but not as easy for the right. At first I tried to compensate by wearing the left glove backwards on my right hand, so I could continue to sew with my dominant hand.

Unfortunately the results look terrible. Therefore I really recommend wearing the glove on the appropriate hand and sewing with your non-dominant one if necessary. If you go slow and take small stitches while awkward…it’s not impossible, and the results look much better.

Wario’s clothes consist of a solid-color yellow tshirt and purple pants with suspenders. I’ve linked suitable options for all three items above, though for my costume I was lucky and found the shirt and pants at my local thrift store. I didn’t think Amazon would have purple suspenders so I made my own. I happened to have some purple fabric at home so used that, though the color match wasn’t the best.

To make the suspenders yourself, put on the pants and and take the following measurements:

Length: measure the length in inches from the waistband in front, up and over the shoulder, and down the back to the waistband in back. Add 3-4″ to this measurement.

Width: the desired width of your suspenders in inches, doubled, plus 1″.

You will first create a tube by folding your fabric in half lengthwise, wrong-sides out, and then sewing a line about 1/2″ in from the open edge.

Once your tube is secure, carefully flip it inside-out. A knitting needle/skewer/chopstick is handy for this! Arrange the fabric so the seam is in the center and iron or finger-press the edges down to keep the strip flat.

The 3-4″ inches extra length added were for use in attaching the suspenders. If your pants have belt loops, first pass one raw edge through the opening of the claw hook, fold the edge in about 1/2″ and then sew down securely. My hook rotates but if yours is stationary be sure to have the side of the tube with the seam at the back.

Once the hook is attached, fold the other raw edge over as well and then sew it to the pants at the rear waistband, again being sure to have the seam on the inside. If you prefer a less permanent option, you can use claw hooks on the other end of the tube as well, and attach on both sides using the belt loops.

If your pants don’t have belt loops you will need to sew all 4 edges into place.

Wario’s pants are actually overalls with big white buttons but it’s easier to create suspenders and then fake the button look on top. If you prefer to make overall straps then instead of attaching claw hooks you will need to make a buttonhole and then sew 2 buttons onto your pants. I was worried buttons might undo during my dance number so I went for the more secure option of suspenders.

To fake the button look, cut two circles out of white felt and stitch (or hot glue) them into place above where the suspenders attach.

With that, your Wario costume is done! I wore this during a performance with fast quick-changes, so having my next costume underneath was the perfect way to add some padding and give Wario his more rounded physique.

Other Mario-themed posts you might like:

This post may contain affiliate links. This means I might make a small commission on purchases made through the links, at no cost to you.


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How To: Easy DIY Super Mario Bros Mario, Luigi, Wario and Waluigi Mustaches

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:

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.

Other Mario posts you might like:

This post may contain affiliate links. This means I might make a small commission on purchases made through the links, at no cost to you.


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How To: Easy DIY Super Mario Bros Hats

Continuing Mario Month, today I’m going to show you how to make really easy character hats for Mario, Luigi, Wario and Waluigi.

I’d looked at a lot of online DIYs when planning my Wario costume for our Super Mario Bros skit, and I liked bits and pieces of each. In the end I compiled suggestions and ideas from a few different patterns and am sharing it as a tutorial so you can use it to make your own costume or cosplay pieces!

For reference, here’s Wario and his hat.

While it’s very similar to the other 3, his is unique in having the white circle cut off by the brim, and by having his initial oversized. As such I decided to make his first, and then focus on the 3 remaining hats for my castmates.

You will need:

The first thing you want to do is draw a template on paper you can cut out. If you have bowls of the appropriate size then you can trace them, otherwise you can use a compass and ruler.

To save paper, draw your circles within each other. In my original template (above) I didn’t have a bowl with the diameter I wanted, so I traced my largest bowl then manually sketched in another circle about an inch wider, so there’s an extra circle showing. Also my pencil marks aren’t as easy to see so here’s a clean template with dimensions:

These dimensions are for an adult-sized hat but it’s easily customizable to make any size you’d like.

Cut out all pieces from your template. The easiest way to do this is to cut out your largest circle (A) and then cut circles B and C from within A. You can cut square D out from circle C after using it, or out of a scrap of paper (so you can keep all 4 pieces of your template for future use).

If you’re planning to make numerous hats you can preserve your template by laminating it with packing tape as I did for the Warp Pipe. You can also cut it from cardstock instead of plain paper for added durability.

Circle “A” is cut twice. One “A” will be left whole and will be the top of the hat. The second “A” will be the lower half. Circle “B” is cut from inside the second circle “A”. It should be centered evenly and then shifted down a bit to leave one section a bit deeper. (In the image below, you can see the hole is a bit higher and to the right vs centered, leaving more yellow on the lower left side).

If you are making Mario, Luigi or Waluigi hats, you can continue to the brim. Wario’s hat is the only one with a two-toned brim, so I traced half of template “B” onto white felt – “(B)” above.

All 4 characters have a white circle on their hats, so you can cut circle “C” from white felt.

Take circle “A” with the hole in it and position so the deeper section is upwards. This is where the details will go.

Position circle “C” into place (noting for Wario that his is the only hat whose circle is more obviously cut off by the brim) and then use matching thread to sew it into place. (You can also use hot glue, as I did for the other hats later in this post).

The other 3 characters’ initials will be cut from square “D”. Wario is the only one with an exaggeratedly large initial on his hat. Cut the “W” from felt and sew (or glue) it into place.

For Wario’s brim, first I lined up the white half on top of the yellow circle “B” and then cut off the excess. Then I sewed the half-circle edge together, leaving the straight edge open. Next I flipped it inside out and smoothed it flat, and then stitched the flat edge shut.

To easily center the brim, fold it in half and mark the center lightly. Do the same on the yellow circle. Line up the two marks, and keeping them aligned, sew the flat edge of the brim to the hat under the initial.

Place this completed lower hat piece upside down on the whole circle “A”. In the first image I had pinned them together, and the second image is after the stitching is complete.

Flip the hat inside-out and you’re done!

If you find the head-hole too small you can cut it larger, but you want to err on a more snug fit as felt will stretch over time. I used the 6″ diameter for all 4 hats and they fit perfectly, staying in place during 6 performances and multiple rehearsals!

The remaining character hats are all identical (except for color and initial) so I did them all assembly-line style. First cut out all template pieces.

Cut the initials from square “D”. I used scraps from cutting out the largest circle. I also switched to a glue gun for the details as it works really well on felt (though since the hats would be getting a lot of rough usage I stuck to sewing for the main construction).

Glue the details into place…

…fold the brims in half and sew them shut…

…then sew the brims into place. After that just sew the two large circles together and flip.

A final, optional step is to iron the edges to help keep them crisp and flat.

Each hat takes under 30 minutes to complete, making this a really quick and easy DIY.

They make a great addition to any Super Mario Bros costume or cosplay and would also be wonderful party favors for gaming-themed celebrations.

Other Mario-themed posts you might like:

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Easy Jughead Cosplay

There are 4 more sleeps until Halloween, and that’s plenty of time to make most of the costume and prop tutorials I’ve been sharing over the last few weeks. Today’s post is so quick and easy that you can make it in under an hour and probably have all the materials you need already!

Back in 2019 Henri couldn’t wear his actual Halloween costume to school because the Neighbor outfit (from Hello Neighbor) had a mask. It didn’t take any time to come up with a school-safe alternate idea for my little brunette food-machine – Jughead! Henri’s a voracious Archie comics reader and we joke that his favorite food is “food” so combining the two was a no-brainer.

The costume is really simple because you can wear any school-appropriate outfit that a teenager would wear. The main key to get the look is Juggie’s trademark hat, and then as a bonus you can include a burger to really sell it.

We went with the comics version, not the Cole Sprouse version from Riverdale, mostly because I didn’t feel like knitting the whoopie cap.

Step 1: A burger. If we’d had a toy or squishy burger I’d have used that, but since we didn’t I went with an easy thought bubble because Mr Jones is always daydreaming of his favorite food.

You can find free clipart online and prepare the image in any software that will allow you to manipulate images. My preference is Excel but you can also use Word, BeFunky, Photoshop, etc. You can also draw the image digitally in something like Procreate or draw it outright on cardstock and color it in with any art supplies you have already. You want to scale your final image to fit as large as possible on a single sheet of paper (if printing it) or can go as large as you like if drawing it on something larger like a Bristol board.

Printable Hamburger in Thought Bubble JELOCADownload

I’ve included the image I used here as a free download. For best results print directly onto cardstock or print onto computer paper and then glue it onto cardstock or cardboard. A panel from an old cereal box or shipping box from the recycling bin is perfect.

To finish the prop and protect it, laminate it with packing tape! I like to cut the image out first so when I laminate I can have a thin edge of tape just past the paper, so no moisture can get in. Cut out your image and lay strips of packing tape evenly across the front of the image, smoothing down any bubbles as you go. Next, flip the image over and repeat the process. Use your fingers to make sure the seal around the edges of the image is tight, and then trim away the excess tape. Finally, tape a stick of some kind to the back. I used a wooden chopstick from takeout sushi that I covered with white electrical tape.

Step 2: The whoopie cap. If there’s ANY key piece for a Jughead cosplay, it’s his unique hat. Cut a strip of cardboard the height of the cap, and long enough to go around the wearer’s head with about an inch of overlap. If you want to paint it gray do that now, though we didn’t bother. Cut the top into points and then try it on the wearer again to make sure it fits and that the points line up where the seam will be.

Draw or paint on the iconic buttons Juggie always has. I used permanent markers and White-Out. Finally, staple or tape the edges together.

That’s all there is to it! So quick and easy it can be ready for school the next day without keeping you up into the late hours of the night.


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Halloween Costume Tutorials

Another year means another roundup of costume-related projects and tutorials! With almost 3 weeks left until Halloween you’ll still have plenty of time to make any of the projects below.

Easily my most popular post (with almost 140,000 impressions on Pinterest in the last 60 days alone!), here’s a step-by-step tutorial on how to make Minecraft Steve & Creeper heads.

Next up (with almost 50,000 impressions) is a similar tutorial, this time for making a Minecraft Enderman head along with a diamond block trick-or-treat box.

Both projects include full charts for game-accurate colors and the exact hex codes for perfect color matching!

If your idea of fantasy is less block-based and more magical, here’s a free knitting pattern for an easy scarf in the Gryffindor house colors.

If training a dragon is more your thing, here’s how to make a viking vest.

If you prefer Pokemon to Night Furies, here’s an easy, last-minute Pikachu costume idea.

If your friends-group themed costume runs more Grease than Greninja, here’s how you can make a super simple Poodle skirt.

Finally, if you’ve got enough knitting time on your hands, you can knit my Baby’s First Superhero Costume pattern as-is with cute designs for boys and girls, or convert the chart and the colors to create your superhero of choice.

Find more tips and tutorials on my How-To page!