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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.

Here’s the full 2022 Mario Month summary:

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.

Here’s the full 2022 Mario Month summary:

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.