I Cosplayed As Maui From Moana And This Is How I Created The Costume

by Patrick Penrose Published Nov 12, 2025

Moana is my favorite Disney movie to date. I knew that I needed to cosplay Maui the moment I saw his character.

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I knew that I needed to cosplay Maui the moment I saw his character. This is how I did it

I Cosplayed As Maui From Moana And This Is How I Created The Costume

Image credits: MDR Foto

First step was to find a good image online to use as a template. The hook is scaled to my height so that it appears proportional

I Cosplayed As Maui From Moana And This Is How I Created The Costume

As a cosplayer, I like a sturdy but light prop that I can carry around all day

I Cosplayed As Maui From Moana And This Is How I Created The Costume

Materials that are convention safe like Pink Insulation Foam work great for prop making. I glued a few layers together and used my template to cut out the hook. Using a wood burning tool I carved the designs into the hook.

I coated the hook with several layers of wood glue for a nice seal before I started painting

I Cosplayed As Maui From Moana And This Is How I Created The Costume

And I added some weathering

I Cosplayed As Maui From Moana And This Is How I Created The Costume

I wanted the rope a little darker than the color I had so I let it soak in some tea

I Cosplayed As Maui From Moana And This Is How I Created The Costume

For the leaves I patterned out dozens of different leaves each one a little different

I Cosplayed As Maui From Moana And This Is How I Created The Costume

Traced the patterns onto craft foam

I Cosplayed As Maui From Moana And This Is How I Created The Costume

I didn’t realize how many color variations were in Maui’s skirt. So many!

I Cosplayed As Maui From Moana And This Is How I Created The Costume

Leaves leaves everywhere

I Cosplayed As Maui From Moana And This Is How I Created The Costume

Theyre getting there

I Cosplayed As Maui From Moana And This Is How I Created The Costume

I attracted all of the leaves to rope using hot glue

I Cosplayed As Maui From Moana And This Is How I Created The Costume

For the necklace I wanted light materials again, so used Apoxie Sculpt

I Cosplayed As Maui From Moana And This Is How I Created The Costume

Traced out some teeth on a sheet of paper and matched the pieces up.

Lots and lots of dust from sanding these. But it wasn’t too bad

I Cosplayed As Maui From Moana And This Is How I Created The Costume

Once they were the shape I wanted I added weathering

I Cosplayed As Maui From Moana And This Is How I Created The Costume

And tied them onto a rope necklace

I Cosplayed As Maui From Moana And This Is How I Created The Costume

The body suit was custom made by my friend in the UK, Wakandanprops

I Cosplayed As Maui From Moana And This Is How I Created The Costume

Some people said I should’ve worn a wig

I Cosplayed As Maui From Moana And This Is How I Created The Costume

Some people said I should’ve shaved my beard

I Cosplayed As Maui From Moana And This Is How I Created The Costume

But I think it turned out perfect

I Cosplayed As Maui From Moana And This Is How I Created The Costume

It’s my version of Maui, I love it, and I hope you do too

I Cosplayed As Maui From Moana And This Is How I Created The Costume

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Patrick Penrose

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