How to Make a Luigi Hat


The Super Mario Brothers are known for their iconic overalls and caps. Luigi's bright green hat can be quickly crafted without the need for a sewing machine or pattern by using fabric and hot glue. Polyester fleece is perfect for this type of puffy cap, as it stretches to fit snugly on any head size and is both comfortable and soft against the skin. Use a few household items like round lids to help create the shape of the hat and Luigi's signature "L" detail on the cap front.

Things You'll Need

  • 1/2 yard green polyester fleece
  • Round 12-inch diameter lid
  • Scissors
  • Hot glue
  • Hot glue gun
  • Small white plastic lid
  • Green permanent marker
  • Fold fleece in half width-wise to create a square that is now 1/2-yard square. Place the large lid in the center of the square and use the permanent marker to trace around the circle.

  • Use the scissors to cut through both layers of fleece, following the outline of the permanent marker, to create two circles of fleece. Place the small cottage cheese container-sized lid in the center of one circle and outline with the permanent marker. Use the scissors to cut the outlined hole out of the center of the circle, creating a small hole for the head to fit through.

  • Without unfolding the leftover scraps from the hat circles, cut through the middle of two perpendicular sides of the fleece all the way to the circular hole in the center so that you now have one separate corner piece. Use the scissors to round the edges of the corners. Because the scraps were doubled up, you now have two rounded scraps to serve as the bill of Luigi's hat.

  • Using the glue gun, apply hot glue to the outside rim of the 12-inch circle with the smaller hole cut into it. Place the full 12-inch circle on top of the one with the hole, matching the edges. Let the glue dry completely, then turn the glued hat pieces inside out.

  • Using the glue gun, apply hot glue to one of the bill pieces. Place the second bill piece on top of the other, matching the edges. Let dry completely.

  • Apply hot glue around the inside edge of the top brim piece. Attach the brim piece along the edge of the hat's hole. Let dry completely.

  • Apply hot glue to the front of the small white lid. Attach the lid to the front of the hat, above the bill, and let it dry completely.

  • Using the green permanent marker, draw a capital "L" in the center of the cap.

Tips & Warnings

  • The hole in the center of the cap may seem small, but fleece stretches and adapts for all head sizes.

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