The Mustache Dache, a mustache themed 5k, commissioned me to build a mascot. Based on my previous costume work, it only took about a day. I'm sure there aren't thousands of people building mustache costumes out there, but hopefully the techniques will help make your build a success. http://mustachedache.com/

If you like the costume, please vote in the upper right corner. Thanks!

Step 1: Materials/Techniques

For this project I used a foam rubber substructure upholstered in a furry black fabric.

You can use either EVA Y-20 foam (ethylene vinyl acetate) or XLPE (Cross-linked polyethylene foam). Both are similar to yoga mat material, suitable for use with hot glue or contact cement, come in a big range of thicknesses for stiffness, and after sealing can be painted if needed. For the strongest permanent bond always use contact cement. Follow the instructions and allow it to dry to a dull finish for ~15 minutes to get maximum grab.

You can cut the foam rubber one of three ways depending on the type of cut:
Scissors: Better on thick material but may leave a rough serrated edge.
Long box cutter: gives a clean edge.
Hot knife: Works well on thin material with very tight contours. 

I've price shopped the entire internet. Cheapest foam: http://www.thefoamfactory.com/closedcellfoam/cross-linked-polyethylene-foam.html. My local fabric store, Joann's Fabrics, always has a weekly 50% off coupon that cuts cost on the fur which is $20/yrd.
<p>Very cool costume, I got a lot of helpfull information from your tutorial. I am building , well I have already built it, (so I guess modifying would be a better description), a company mascot. We are a small local company, so cost was important, so I went at it with, only enough knowledge to be dangerous. It is a reusable shopping bag, the front and back are vinyl banner printed by a company that did it for cost, with the side a light stretchy material for breathability and they are sewn together. I then built a frame out of PVC pipe, contectors and glue. I attached a few ppictures. The problem being my make shift harness system is not always stable and the character is probably out a least once a week, so the vinyl is not holding up very well. </p><p>So I was looking at foam for the character, but I am worried about how hot it can get, also I was looking at using fiberglass tent poles instead of pvc. Anything I can use that is recycled help me keep the cost down even if it is a bit more work. I could sure use some advice from someone who knows what they are doing.</p><p>Thanks!</p>
Ha ha
Wow. Just wow.
Every time I see the main photo I laugh. SO GOOD
LOVE IT! ALL u need is MILK! <br>Nice job.!!.check out mine what u think? made out of card boards and tape lol Vote if you like show some love in return :-)
This is awesome. Nice legs!
loll... i loved your costume =D <br>
Thank you so much.
That's amazing! Now I can be a giant mustache for Halloween! Yay!
I would love nothing more than to see a herd of mustaches roaming the streets.
This is the coolest thing EVER!!!
Haha this is awesome!
where did you get googly eyes that big?
http://mcphee.com/shop/giant-christmas-tree-googly-eyes.html<br><br>Archee McPhee.
The mustache craze cracks me up! I adore the costume well done!
Ha. Thanks! I'll have a dragon costume and a herd of minion costumes posted in a few weeks. I know I'm an addict when I find a way to make 7 costumes per year.

About This Instructable




Bio: I am a foam fabricator and own a costume and prop design company called Partybot Designs. I take on commissions of any scale from cosplay ... More »
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