instructables

Cardboard Mario Kart Costume

by KlinskyLabs

In 2018 a group at work decided to participate in a Halloween costume contest. We settled on Mario Kart as a theme and
I set about to design a kart that could be made from cardboard. We needed to make 4 of them (plus 2 for my kids) so I
tried to come up with a design that I thought looked good but wasn't too complicated to make. I was pretty happy with
the nal result so I am sharing the design here along with instructions and photos.

Remember, have fun. These instructions cover what I did but I encourage you to be creative.

(Don't get concerned if it looks like my kart is a lot smaller than yours. For the purposes of these instructions, I built a
half-sized kart.)

Tools:

Printer
Metal straight edge or ruler
Utility knife
X-Acto knife
Sharpie marker
Pencil
Pliers
Scissors
Small clamps (nice to have)
Self healing cutting mat (nice to have)

Supplies:

Cardboard (and lots of it)

Wood glue (I used Gorilla brand Wood Glue)
3M Extreme Hold Duct Tape
Metal wire coat hanger
Drinking straws
Card stock that your printer can handle
Clear tape (I used clear packing tape)
Painter's tape
Paint brushes
Acrylic or spray paint
Black
Yellow (I used Krylon ColorMaster Bauhaus Gold - Gloss)
Cardboard Mario Kart Costume: Page 1
 plus colors of your choice. I used:
White (Krylon ColorMaster White - Gloss)
Red (Krylon Foil Metallic Red)
Blue (Krylon Foil Metallic Blue)

https://youtu.be/IBeUT9z4TZU

Step 1: Printing the Patterns

Cardboard Mario Kart Costume: Page 2

There are a number of PDF patterns to print. When you
print them from Adobe Acrobat, be sure to print them at
"Actual size". Your printer might not print all the way to
the edge of the paper but that won't matter. I suggest
printing the patterns to card stock to make it easier to
trace.
Many of the patterns span multiple pages. You should be
able to tape the pages of them together without having
to trim the paper. I like to use clear packing tape, but you

can certainly use any clear tape.

Step 2: Prepare Your Cardboard

Assuming you are using cardboard boxes, look for the Also, pay attention to the "grain" of the cardboard. By
seam. I suggest separating the box at the seam in orderthis, I mean the orientation of the corrugation in the
to get the most usable area from the box. center of the cardboard. When layering cardboard, it will
be strongest when one layer is rotated 90 degrees from
The patterns provided here assume that your corrugated the other layer. I use this method for the steering wheel
cardboard is 1/8 of an inch thick. to give it strength.

Step 3: Body - Side Panels

Cardboard Mario Kart Costume: Page 3

Print out the multi-page pattern for the body. My will need to be folded. Refer to the pattern to look for
cardboard wasn't large enough for the full body so I cut the dotted line.
it in 2 sections (left & right)
Press the edge into the cardboard to establish the crease
Start the folding process with the side panels. Put the and then fold the side panel upward.
nicer side of the cardboard on the oor. Now, place a
metal straight edge along the line where the side panel

Download

https://www.instructables.com/ORIG/FT3/R3VV/KOD7RZDK/FT3R3VVKOD7RZDK.pdf

Step 4: Body - Rear Bumper

Cardboard Mario Kart Costume: Page 4

With the nicer side of the cardboard on the oor. Use a
metal straight edge to put along the edge where the
rear bumper needs to be folded. Press the edge into the
cardboard to make a crease and then bend it upward.
Now do the same for the triangular part at the end of the
bumper.
place. Do a test t to make sure the bumper can be
folded into plate. Try to get the top and bottom edges of
the rear bumper to line up with the top and bottom
edges of the side panel. When things look good, apply
glue to the triangular tab and then glue it to the inside
of the side panel.

The triangular tab will be used to glue the bumper into

Cardboard Mario Kart Costume: Page 5

Step 5: Body - Front Bumper

For the curved sides of the front bumper, use the metal
straight edge technique to apply creases every 1/4" or so
into the cardboard. Start at the point where the bumper
separates from the top of the body and then continue
out to the far end of the bumper. Apply these creases to
the left and right sides of the bumper.
Once the creases have been made, bend the bumper
around the side and press it along the side panel to
make sure it has the right shape. Once it seems to have
the right amount of curve, apply glue to the 2 small tabs. wheel.
Also apply some glue to the front inside edge of the side
panel. About an inch wide section will do.
Now, bend the edge of the front bumper around the
curve, touching it to the 2 small tabs. Put the end of the
bumper on the inside of the side panel where you
applied the glue. Make sure that the curve of the front
bumper is still allowing it to rest against the 2 small tabs.
The front bumper will probably stick down a bit further
than the side panel but this will be hidden by the front

Cardboard Mario Kart Costume: Page 6

Cardboard Mario Kart Costume: Page 7
Step 6: Connect the Body Panels

If you were not able to cut the kart body out of a single piece of cardboard, now is the time to attached the 2 halves
together. Take a 4"x4" square and then glue it to the underside of the 2 pieces, attaching them together.

Take one of the 2" x 4" tabs and then follow the same process as above to connect the halves of the front bumper
together.
Cardboard Mario Kart Costume: Page 8
Go through the same process to join the other end of the body.

Step 7: Seat

Like we did on the body, use a metal straight edge to put the creases indicated on the pattern onto the cardboard of the
seat. There are tabs for you to apply glue to as you can see in the photos. When you fold the seat together, those tabs will
keep it closed. Try to get bottom of the side panel to meet up with the back panel of the seat.

Cardboard Mario Kart Costume: Page 9

 1

1. Try to get the edges of the side panel and front panel to line up.

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Step 8: Body - Slot for the Seat

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Now it's time to make a slot for the seat to attach to the
body. I went with the angled side of the seat as being
toward the back of the kart but it can work either way.
Center the seat and place one tab of the seat against the
back edge of the hole for the driver. This tab will fold
under the kart body. For the other tab, fold it toward the
back of the kart and make sure the seat is pressed down
on the kart. Use a pencil to mark the corner where the
tab of the seat meets the back edge of the seat. We will
be making a 1/8" slot in the body for that tab to be
Cardboard Mario Kart Costume: Page 11
inserted into.
Now that you have the marks, remove the seat. Draw a
line connecting the 2 marks. Now make a matching line
1/8" inch closer to the center of the kart. Cut this slot out
with an X-Acto or utility knife. Do a test t of the seat to
make sure the rear tab of the seat ts in the slot.
Remove the seat. Don't glue the seat into place at this
point and just set it aside.
 1 2

1. Make a mark 1/8 of an inch toward the center of the kart

2. Make a mark 1/8 of an inch toward the center of the kart

1. Test fit the seat into the slot but don't glue it yet. Save that for after it's
painted.

Cardboard Mario Kart Costume: Page 12

Step 9: Front Console

Trace the pattern for the front console onto cardboard along the creases to match the pattern.
and then cut it out.
Apply glue to the tab indicated, and then fold it under
Now it is time to make the folds. Refer to the pattern to the rectangular side. Do the same to the tab on the
see where the folds need to be made. I pressed the side opposite side.
of a metal straight edge into the cardboard along the
line where I wanted the fold to be. Bend the cardboard

Cardboard Mario Kart Costume: Page 13

 Download

https://www.instructables.com/ORIG/F7N/30Q4/KOD7RZDI/F7N30Q4KOD7RZDI.pdf

Step 10: Body - Attach the Front Console

Flair the tabs of the front console outward. Now place
the front console centered on the front portion of the
body.
Get it centered as best you can and then draw pencil
marks to indicate where the tabs meet the base of the
front console.
rectangular slot.
You should now be able to insert the tabs from the
console and move it into place. Try to get the front
console positioned just right. It is important to get it
centered and try to make it ush with the front of the
kart.

The cardboard tab is probably 1/8" thick. Make pencil
marks 1/8" away from your marks toward the center.We
are making a 1/8" slot for each of the tabs.
Once the marks for the slot are drawn, cut out that
On the underside of the kart, nd the tabs and then
bend them outward. You should now glue these to the
underside of the body after double checking the t of
the console.

Cardboard Mario Kart Costume: Page 14

Cardboard Mario Kart Costume: Page 15
Step 11: Steering Wheel

Take the lower part of the steering wheel (with the cross) and the upper part (just a circle) and layer them. Pay close
attention to the grain of the corrugation by looking at the edges of the pieces. Line up the corrugations to be the same
and then rotate the top later by a quarter turn so that its grain goes against the grain of the lower part. You will want to
glue the pieces together in this orientation. It will make the part stronger.

Cardboard Mario Kart Costume: Page 16

 Download

https://www.instructables.com/ORIG/FA0/L7Z3/KOD7RZD9/FA0L7Z3KOD7RZD9.pdf

Download

https://www.instructables.com/ORIG/F4K/O2VS/KOD7RZDA/F4KO2VSKOD7RZDA.pdf

Step 12: Wheels - Sides

Cut the sides for the front and back wheels. The inner
side of the wheel has the slot for the mounting tabs.
Cut out the wheel mounting tabs. You will use 2 tabs per
wheel.
those tabs to the surface of the cardboard.
Now, fold the tabs radiating around the edge of the
circle toward the side where the mounting tabs are
glued.

Hold 2 tabs together and slide the pair so half of the
length is sticking out from each side of the inner wheel
side.
On one side of the part, fold the tabs outward. Glue
On the other circle, fold all of the radiating tabs to one
side of the circle.
Prepare the parts for all 4 wheels.

Cardboard Mario Kart Costume: Page 17

 Download

https://www.instructables.com/ORIG/FWR/VC8G/KOD7RZDH/FWRVC8GKOD7RZDH.pdf

Download

https://www.instructables.com/ORIG/FTQ/CHV6/KOD7RZDE/FTQCHV6KOD7RZDE.pdf

Download

https://www.instructables.com/ORIG/FRO/LZAW/KOD7RZDC/FROLZAWKOD7RZDC.pdf

Cardboard Mario Kart Costume: Page 18

Step 13: Wheels - Treads

When orienting the cardboard for the wheel treads, try the length of the tread.
to get the grain of the cardboard to go across the the
length of the tread. This will make it easier to curve When you are done, you should see the cardboard adopt
them. a curved shape.

Press the metal straight edge on the surface of the tread If the strip is a bit long, you can always trim it up later
parallel to the grain. Fold the cardboard upward in order when you assemble the wheels.
to make a crease. Now slide the straight edge over about
1/8 inch and make another crease. Keep doing this down

Step 14: Wheels - Assemble

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Grab an inner and outer circle for one of the wheels as
well as the appropriate tread.
Start by gluing one tab from each of the wheel sides to
the tread. Try to get the edge of the tread to line up with
the outer surface of each wheel side.
Once the glue has dried and the parts are secured,
continue to glue half of the remaining tabs on each side
and attach the tread.
Cardboard Mario Kart Costume: Page 20
After the tread is glued around half of the wheel, apply
glue to the rest of the tabs and attach the tread. When
you get toward the end, you might need to trim the end
of the tread to make it meet up properly. When you have
the length right, apply a little glue across the edge of the
tread end. Worst case, if the tread comes up a bit short,
you can cut a small piece to ll the gap an glue it in
place. It will all be painted black anyway.
Complete this process for each of the wheels.
Cardboard Mario Kart Costume: Page 21
Step 15: Shoulder Harness - Brackets

Gather up the following items:

Metal hanger
Straws
4 x Cardboard strips (6" x 2")
Sharpie
Cardboard Mario Kart Costume: Page 22
 Scissors or utility knife
Pliers

Take a cardboard strip and fold it in half.

Cut a 2 inch section of the plastic straw.

Straighten the metal coat hanger. You will need to cut o a 5 inch section.

Use the Sharpie to put marks at 1", then 1/2", then 2", them 1/2", then 1". This is where the bends will need to be.

I suggest starting with making right angles on either side of the 2" section. After that, bend each of the 1" sections
together to close the rectangle. For now, don't close the rectangle completely.

Now, take a 2" section of straw and you will need to put the two 1" ends of the coat hanger through it and then close the
rectangle. It's okay if the straw gets a lot of creases in it.

Now take your folded cardboard strip and put it through the metal rectangle so that the straw is in the fold of the
cardboard.

With the cardboard folded, make sure the straw is all the way in the fold of the cardboard. At this point, you can glue the
cardboard sides together.

You will need to make 4 of these.

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Cardboard Mario Kart Costume: Page 24
Cardboard Mario Kart Costume: Page 25
 Download

https://www.instructables.com/ORIG/FJE/9SOO/KOH6RO58/FJE9SOOKOH6RO58.pdf

Step 16: Shoulder Harness - Straps

I REALLY like the 3M Extreme Hold Duct Tape for this this length. Lay it sticky side up on the mat.
project because it looks really good for shoulder straps
and it is also very strong. Take 1 of the brackets and loop the tape through the
metal loop. Move it to 3 inches from the end of the tape.
To gure out the length for the shoulder harness straps, I Fold the tape over and adhere it to itself. The tape is very
cut strips of paper and taped them together. I then used sticky so try to get it aligned right the rst time.
these as a proxy for shoulder straps and put them over
the driver's shoulders to see how long they should be. As After you get a bracket attached to each side of a strap,
a rough guide, you can probably take the length from cut additional strips of tape and apply them to the
the driver's waist to their shoulder and double it. exposed adhesive part of the straps. You don't need to
worry about the lengths being precise but do try to get
Once you have the desired length of the straps, add 6 the sides to line up so that there isn't any adhesive
inches (3 inches on each end) to account for the part exposed.
that will attach to the brackets. Cut 2 strips of the tape to

Cardboard Mario Kart Costume: Page 26

Step 17: Time to Paint
Paint the seat, steering wheel, and all of the wheels
black. You won't need to paint the tabs that are sticking
out of the wheels but do paint both side of the wheels.
As mentioned before, I kept these parts separate from
the body to make the painting easier.
To get nice clean lines on the wheel rims, I printed the
attached patterns on card stock and cut them out. I just
painted them with yellow paint and set them aside to be
attached later. The rims on the rear wheels are a bit
larger that the ones on the front.
Cardboard Mario Kart Costume: Page 27
For the kart body, I painted it all white as a base coat. I
then added
red and blue accent colors. You can see what I did for my
Mario kart in the attached PDF. This is your kart though.
Try to replicate the color scheme of your favorite
character or just be creative.
When you go to paint the front console, try to refer to
the Steering Wheel Mounting Guide to see where the
steering wheel will be touching the front console. It will
be best if you can leave some exposed cardboard in
order to provide a better bond with the wood glue later.
 Download

https://www.instructables.com/ORIG/FQG/47DT/KOD7RZDG/FQG47DTKOD7RZDG.pdf

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https://www.instructables.com/ORIG/FYD/WRIU/KOD7RZDJ/FYDWRIUKOD7RZDJ.pdf

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https://www.instructables.com/ORIG/F9V/YILC/KOEBVGIQ/F9VYILCKOEBVGIQ.pdf

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https://www.instructables.com/ORIG/FN0/29P4/KOZRH7GH/FN029P4KOZRH7GH.pdf

Step 18: Wheels - Attach Rims

Now that everything is painted, it's time to get out the glue again. You can glue the yellow rims onto the wheels.
Remember, the smaller rims go on the smaller wheels. There are rim mounting guides here in case you want some help
in getting them centered.

When I initially built the karts, I used spray contact cement but later I have also just used a thin layer of the wood glue.

Cardboard Mario Kart Costume: Page 28

 Download
https://www.instructables.com/ORIG/F8K/50QD/KOEBVD29/F8K50QDKOEBVD29.pdf

Download

https://www.instructables.com/ORIG/F36/NKVI/KOEBVD28/F36NKVIKOEBVD28.pdf

Step 19: Body - Attach Seat

Take the tab of the angled side of the seat and slide it into the slot in the body that we made earlier. Make sure the seat is
ush with the body.

Flip body over and glue down the tabs of the seat.

Cardboard Mario Kart Costume: Page 29

Step 20: Body - Attach Wheels

Gather up your wheels. We will be putting the tabs you
made earlier to use.
For reference, the tab is closer to the top of the wheel
than the bottom. This is true for the front and the rear
wheels. The smaller wheels are for the front and the
larger ones are for the rear.
Pinch the tabs together and slide them through the
mounting slot on the side panel of the body. Make sure
the wheel is ush with the side panel. When it seems
good, fold the tabs apart and glue them down to the
inside of the body.
Complete this step for each of the wheels.

Cardboard Mario Kart Costume: Page 30

Step 21: Body - Attach Shoulder Harnesses

Looking at the underside of the kart, start with the area Make sure that the shoulder harness straps are not
where the seat attaches to the body. Glue a shoulder twisted.
harness bracket next to the tab of the seat. The metal
part of the bracket should be just extending past the Attach the other shoulder harness in a similar manner.
edge of the body.
When you go to wear the kart when you are done, the
Now take the bracket on the other end of that shoulder straps will cross along your back. This should help a little
harness and cross it over to the opposite side of the kart to keep the straps from falling o of your shoulders.
to underside of the front console. I have a piece of
cardboard attaching the left and right sides of the body
so I glued the brackets next to it.

Cardboard Mario Kart Costume: Page 31

Step 22: Body - Attach Steering Wheel

For the steering wheel, you will be gluing the side with the cross to the kart. There is a mounting guide here in case you
want some help.

Cardboard Mario Kart Costume: Page 32

 Download

https://www.instructables.com/ORIG/F4R/5UDH/KOEBVCA2/F4R5UDHKOEBVCA2.pdf

Step 23: Final Touch: the Emblem

For the emblem on the front of the kart, I used my
Silhouette Cameo to make adhesive vinyl stickers. You
could also just print out an emblem and glue it on. There
are many resources on the internet for the various
emblems. Just print it out in a 6 inch circle and cut it out.
That's it! The kart is done. Just a reminder, when putting
on a kart, have the shoulder harness straps cross over
behind you.
Have fun!

Attached here is a mounting guide that you can use to

get it positioned correctly on the front console.

Download

https://www.instructables.com/ORIG/FBO/8XO5/KOEBVCA1/FBO8XO5KOEBVCA1.pdf

Cardboard Mario Kart Costume: Page 33