Bowser’s not the sort of character you want to befriend, but he looks downright cuddly when he’s translated to a costume. Instructables user CassiniCloset built the Super Mario character over the course of nine months. All in all, she spent about 200 hours on the ensemble. The effort paid off; it’s amazing to flip through the in-progress pictures for the costume and see how Bowser came together. She said the Koopa’s head was the most difficult part to make and she used the balaclava foam method to build it:
I wanted to make it as a balaclava foam technique. And started with the frame of the eyes. I wanted to make the eyes deep so they could have a ‘follow-me effect.”
I wrapped and glued this frame piece to the balaclava so I’d have room for my face. And from there added eyebrows and cheeks and the begging of the muzzle. Bowser’s muzzle is a continuous line of circular shapes. I must admit it was not easy to replicate. I do spend a lot of time cutting shaping, sculpting , gluing back on pieces. To make it look right to my own satisfaction. And it does look like a mess but the outcome is worth it.