My youngest son is going to be Super Mario from the Nintendo DS/Wii Games for Halloween this year.

Most of the time I am perfectly fine with purchasing costumes, as I am a full time working mommy with way to many commitments.

However, I am also trying to be reasonable that with three children, purchasing costumes at $30 plus a pop can get expensive, and if there is a way to make a costume cheaper, I will try to do it.

That was the case in making my son's Mario Costume.

This Instructable is a remix (meaning my own photos and wording) of the Mario Hat Instructable by Pie Popper.

I followed her Instructable for the basis of making this hat, and the only reason I chose to do another Instructable was because hers does not have photos of the process. I would like to note that in the comments section, she plans on taking photos, but I know how it is to be busy and not get the chance to do those kinds of things.

Thank you Pie Popper for the idea! I am very grateful for your tutorial!

Step 1: Materials & Tools

Materials & Tools Used:

approximately 1/4-yard to 1/3-yard red fleece*
white felt scrap for a two and-a-half to three (2-1/2 to 3) inch wide circle
sewing machine
matching red & white thread
eleven (11) inch diameter plate
seven (7) inch diameter plate
five (5) inch diameter plate (I used the backside of the 7-inch plate)
mason jar cap that is approximately 2-1/2 to three (3) inches diameter
scissors and/or self healing mat and cutter

*Note: I used just under 1/3 of a yard to create the hat. I'm glad I had extra, just in case I made a mistake, which was possible for me as I'm not a great sewer.

Step 2: Cut Out the Larger Pieces

The red fleece was folded in half so I could make two (2) of the same sized pieces.

Using my 11-inch diameter plate, I traced the outside edge of the plate on the backside of the fleece (at least I think it was the backside.)

I used a blue-colored photo pencil that I've had, and I would have used chalk if that didn't work.

I cut around the edge of the plate using my self-healing mat and rotary cutter, so I could get through both thicknesses of fleece.

Step 3: Cut Out a Hole for the Head

Using one of the eleven (11) inch diameter circles, center a 5-inch plate (or other circular item) to trace around.

In my case, I used the underside of my seven (7) inch diameter plate.

Cut the hole out and try on the head you are making the hat for.

The original Instructable for this (Mario Hat by Pie Popper) stated clearly that the piece would stretch, and it really does!

Step 4: Create the Brim

Using the outside of my seven (7) inch diameter plate, I traced and cut one circular piece.

After determining what I think was the backside of the fleece, I folded the circle in half and sewed the the edge, leaving a small hole at the end to turn it.

After turning it, I hand sewed the opening shut.

Step 5: Sew the Brim Onto the Base of the Hat

Again trying to determine what the backside of the fleece was, I placed the brim on the top of the better side of the 11-inch piece of fleece that has the hole.

I pinned the brim around the hole opening, trying my best to stay along the edge of the opening curve.

I sewed the piece on, through all three thicknesses.

The last photo shows the brim attached to the head opening piece.

Step 6: Create the M Logo

Mario's hat is not complete without the uppercase "M" logo.

I measured the inside piece of a Mason Jar lid to get a 2-3/4 inch sized circle on a white piece of felt.

For the M you see on the final product, I hand drew the M onto the red fleece prior to cutting it out.

I over estimated the first "M" I created.

For the second time I made an "M" I still hand drew it, made it smaller and trimmed the edges as needed to get it to fit in the white circle.

I sewed the letter onto the white circle using the sewing machine, but in retrospect, I probably should have hand sewn it with a blanket stitch for an extra special touch.

Oh well.

Step 7: Sew the Logo Onto the Hat

I chose to hand sew the logo onto the hat with a blanket stitch.

I did the majority of the work while at a doctor's visit, and the hand sewing took me about half an hour.

Sewing the logo by hand is of course optional, and the logo could be sewn onto the hat using the sewing machine.

Step 8: Sew the Top of the Hat

The last step in completing this hat is to sew the second 11-inch circular piece to the brim and logo piece.

Place the better side of the 11-inch circle to the brim/logo side (or better side) of the head opening piece.

Pin the two pieces together.

Sew around the outside edge of the two pieces, ensuring that the brim doesn't get caught in the stitches while sewing.

Remove the pins, trim all the ends and turn the hat inside out for a final product.

My son loves his hat and it's hard to get him to wait until Halloween to wear it. We'll be using it as a fun item after Halloween as well, and knowing my son, he'll probably wear it when we play Super Mario Brothers together!