Instructables
Picture of Mustache Mascot Costume
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!
 
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Step 1: Materials/Techniques

Picture of Materials/Techniques
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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.
donna.funk.129 made it!4 months ago

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.

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.

Thanks!

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duckymomo45 months ago
Ha ha
Wow. Just wow.
Every time I see the main photo I laugh. SO GOOD
sokiboi781 year ago
LOVE IT! ALL u need is MILK!
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!
sabu.dawdy1 year ago
loll... i loved your costume =D
Partybot (author)  sabu.dawdy1 year ago
Thank you so much.
beme20131 year ago
That's amazing! Now I can be a giant mustache for Halloween! Yay!
Partybot (author)  beme20131 year ago
I would love nothing more than to see a herd of mustaches roaming the streets.
bob30301 year ago
Cool
Aubryn1 year ago
This is the coolest thing EVER!!!
Haha this is awesome!
where did you get googly eyes that big?
Partybot (author)  thematthatter1 year ago
http://mcphee.com/shop/giant-christmas-tree-googly-eyes.html

Archee McPhee.
poofrabbit1 year ago
The mustache craze cracks me up! I adore the costume well done!
Partybot (author)  poofrabbit1 year ago
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.