- Before we begin, download the Template by going HERE. The file is a PDF file that is 2 pages. Change your printer to landscape if it doesn't automatically adjust that for you.
- Print and cut out all of the template pieces you need. (One of Template 1 and One of Template 2)
Step 1: Trace and cut out Template 1 on poster board or card stock. Cut out a patch and a letter for your visor.
Step 2: Fold the oval in half using a valley fold. Essentially bring the bottom of the oval up to meet the top and crease.
Step 3: Match up the crease you just made on your visor with the half way line on Template 2.
Step 4. Using a scoring tool, or your best approximation of one, score your visor along the curved line.
I took a picture of the score line so you can see it. You might need to go over it several times if you use poster board. Card stock would probably be fine with just scoring it one time.
Step 5: This is the only tricky part, but once you get one, the rest are easy! You want to crease the bill of your visor down along the curved score line. It helps to gently curve the whole visor. It makes the score line easier to follow.
Step 6: Attach your patch and letter with glue. I used a glue stick, but just about anything should be fine.
Step 7: You can punch some holes using the guide on the template and tie on some elastic thread. You can also eye ball it, or just staple on some 1/4" elastic too. I made all mine in slightly varying sizes to accommodate different sized heads.
Here were the hats I made last year for the party.
Here they are in action!
Here is the link to download the template again: Mario and Luigi Visors Template
If you have any questions let me know! If you make some, I'd love to see pictures. Feedback is really the best.