Tutorial - Making Mario Bros Hats

12:43 PM

UPDATE:  If you need an adult size Mario hat, use THIS post.

A few years back my kids were obsessed with Angry Birds.  I'm mean OBSESSED!  I thought they'd never be over it.  But alas, time moves on and so do kid obsessions.  It's nearly birthday time again at our house and all my son wanted for his party were Mario and Luigi hats!

Easy Mario Brothers Hats
 A few years ago I made Angry Birds Loot bags for a birthday party.  That experience taught me that you can make just about any cartoon character if you break it down into basic shapes.  Here's the link for the Angry Birds Loot Bags.

Easy Angry Birds Loot Bags

In this tutorial I'll show you how to make the easiest Mario Brothers hats around.  Since I'm a visual person I took LOTS of pictures.  Probably too many - but you'll see.  This project is wicked easy!

For this project you will need:
Makes 10 hats

1/2 yard green fleece
1/2 yard red fleece
white fleece or felt (scrap pieces work fine)
Red thread
Green thread
White thread
1 dinner plate
1 bowl
marker (I used a sharpie)
sewing machine

What to do:

Gather all of your materials.  This won't take long at all!
I chose a 10.5" dinner plate (mostly because that's what I had on hand) and a bowl that was approximately 1/2 the size of the plate.

Plate and bowl for tracing
10" plate
5.5" bowl

 Here is a picture of the final hat.

Finished hat on my 6 year old
 If you need a larger/floppier hat choose a larger plate and bowl.


 Fold the fabric in 1/2 and trace around the plate.  Center the bowl inside the plate circle and trace around the bowl.

Trace the plate and bowl using a marker

 Cut out the larger circle.  (because the fabric was folded you'll end up with 2 large circles)

Cut out the large circle
 Next carefully cut out the smaller circle.  You will end up with 3 circles like this.

Cut the smaller circle
  Fold the smallest circle in 1/2 and cut on the fold.

Fold the smallest circle in 1/2 and cut on the fold

Hat pieces

Now for the monogram.

Use scrap fleece or felt
The circle should be small enough to fit inside the hat band

Cut the white fabric into a circle that is small enough to fit on the hat band.

Using fabric scraps, cut a small red square

Cut a red square small enough to fit inside the white circle.

Cut the small red square into the letter "M".

Fold the square in half
Cut a notch on top of the fold
Cut the bottom like this
Look, you made an "M"
Make sure it fits!
 Make sure that you're "M" fits inside the white circle.  Trim as necessary.


Now you're ready to sew!

Using red thread, sew the "M" to the white circle.

Stitch the M in place

Set the letter aside.  It's time to sew the hat!

Sew the outer edges of the hat
Sew the outer edge of the 2 larger circles together.

Turn it inside out

Turn the hat inside out.

Sew the hat bill
Stitch the egde just like this!

Sew the rounded edges of the smaller circle together.  Turn it inside out.  At this point your project should look like this.

Almost done!

Center the initial on the hat band.  Using white thread, sew it in place.

Center the letter

Sew it in place

Time to sew the hat's bill.  Center the bill over the letter.  Stitch the hat bill in place.

Center the bill over the letter
Sew the bill in place
That's it!  You're done!

TA-DA!  All done!

Wasn't that so easy!!!!


Now if you're me, you do this again 9 more times to please your kid!

Mario Hat Bonaza!
I sewed and sewed just dreaming of the glimmer in my son's eye!

But wait...what's that you say son!?  Oh, you've changed your mind you say?  Now that I'm all done sewing you don't want Mario and Luigi hats!?   To quote my mother "dirty words and nasty thoughts!" Turns out the young master is worried that his friends aren't as into Mario and Luigi as he.  Turns out he's afraid he'll get teased if I bring "baby dress up clothes" to his school party.

The good news is that mommy is as crafty a business woman as she is a hat maker.  And so I posted the hats on etsy!

Another mom needed 16 hats.  So I whipped up a few more and shipped them off to Brooklyn!

Etsy saves the day!

Let's just hope that her son is sweet and grateful!

I still don't have a give-away for my son's party, but I'm thinking he might not deserve one.  I'll keep you posted!

Happy Creating!

2 Mario's
For more crafty ideas, click HERE!

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  1. I don't know how old this post might be but i'm glad you did post. You are saving Both of my Grandsons Halloween costumes. With nice easy instructions I will be done in no time. Thank You

  2. Amazing post and easy too:)

  3. Thank you so much! I decided to make my youngest son's costume this year instead of paying a ridiculous amount of money for a flimsy piece of material that will be in tatters by the end of the night; I was just worried about how I was going to pull a hat out of thin air. Your post was amazing and quite possibly saved his Luigi costume, keep up the great work and again, thank you!!

  4. That's for this post. I was given a Luigi costume without a hat. Was worried I'd have to buy a whole new costume because of it. Looks simple enough. Halloween is saved. My youngest was not going to be Mario if his brother wasn't Luigi.

  5. That's for this post. I was given a Luigi costume without a hat. Was worried I'd have to buy a whole new costume because of it. Looks simple enough. Halloween is saved. My youngest was not going to be Mario if his brother wasn't Luigi.

  6. Thank-you, thank-you! I'm very visual too and it didn't seem like too many pictures at all!

  7. Thank-you, thank-you! I'm very visual too and it didn't seem like too many pictures at all!

  8. How do I do this without a sewing machine?

    1. If you're just making one hat you can easily hand sew it. If you're making a lot of them you'll need a machine otherwise it could take you FOREVER!

  9. This is an awesome tutorial. My son is turning 6 and he is having a Mario/Luigi Party. He will get the hats whether he wants them or not!!!

  10. Thank you for this tutorial. As I was reading this, I was thinking that I could go buy all the supplies, haul my sewing machine up from the basement and the kid will change his mind and decide to be a robot or a potato for Halloween. Your son's reaction made me laugh. I am going to go for it!

  11. Girl! I so feeling your PAIN and frustration....along with the ability to out cuss you (because I'm older with more practice). Thank you so much for this. I've made a knight shield and sword and tunic.....grandma?????? I want to be Mario for Halloween! grrrrrrrr Feeling your pain, but grateful for the tute. You saved me a tone of time and frustration:) Kelly

  12. Thank you for this! One Halloween costume down. (Thankfully, this isn't the kid who changes his mind all the time.....that one wants to be a Peregrine falcon!!!! How the heck am I supposed to do that?)

  13. I totally just googled to make sure that Peregrine falcon wasn't a super hero. Lol!

  14. Thanks for this great tutorial & the links for adult sizes. I am making my granddaughter a Princess Peach dress for Halloween (store bought ones were really cheap & ready to fall apart)....so why not make hats for her parents, as well. They can come up with the clothes easily enough for Mario & Luigi. Your directions are easy to follow & I really appreciate the photos. They enjoy playing Mario games, so I think I'll make a child size hat so Ella & her dad can wear their hats while playing...she'd love it! A thankful seamstress!

  15. Excellent post, I was having lots of trouble trying to figure out how to make Marios hat, tutorial was clear and simple. Keep posting! Thank you very much!

  16. Thanks for your tutorial. I just made a Mario hat for my daughter.

  17. Hiiii thank you so much for posting this! I wanted to thank you privately but couldn’t find your email. Wish I could send you a picture of the Luigi hat my daughter asked for so she could be Luigi for Halloween this year. I used an XXL green T-shirt to make the shirt and hat so they would match, for the hat, I used fusible for structure and a little bit of batting for volume.
    Thank you so much!

  18. Thanks for the super easy tutorial. Hahaha your life if your son sounds like mine!!!! That is exactly something they would do to me. I am actually going to be making these for our elf on the shelf dolls. I can't wait to see their reaction.