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:
felt – each hat will require enough felt of one color to cut circle A twice. Circle C and square D require minimal amounts in contrasting colors.
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.