Lego Mario - Super Duper Replacement Pants

Late one night, I stepped on, and painfully broke, my child's Lego Mario pants that were left on the floor.  Never mind that their room should have been tidy, I was still branded “worst parent ever”.

Thankfully, inspiration struck, and instead of buying a boring replacement set, I decided to up Mario's game and create Super DUPER Mario pants. Because hey, why just replace something when you can upgrade!

Needless to say that my status also got upgraded to “most awesome parent ever”.  See the video for a sample of the pants in action:

Now, let's get to the details…

Printing:

Everything can be printed at a 0.1mm layer height and a 0.4mm nozzle.  For strength, use 50% fill on the pins, the pants can have a fill of 15%.  For the pants, I used everywhere supports at the “snug” setting and it worked really well.  There isn't a huge amount of support material but it is a necessary evil on this print.  

I have included some 3mf files that orient the parts, adds support where appropriate, and also includes a colour change for Mario's shoes and the “Icon” for the Style 1 pins.

For material I used PLA but PETG works also.

The fit is important so you may need to tweak the model slightly depending on your printer. 

There is a very small nub on the outer edges of the pant windows to add some snugness.  If the pins are loose, the spring contacts on the Lego Mario body may push your pin back out again.  This isn't the end of the world if it happens as you are holding on to Mario during play anyway, so you can easily hold the pin in place in the event you don't get an ideal fit the first time around.

How it Works:

Lego Mario essentially has a binary switch system that the various “pants” activate via pins. 

Below is a current schematic of the different combinations currently available (as far as I know):

Therefore, my “pins” are coded to activate the associated switches.

I have include two styles of pins:

Style 1 is a single piece with a colour change after the 0.5mm level.  This will give you an easy way to print out a durable pin.

Style 2 this is a two-piece design.  The base plug has a hole in which the post of the button can fit.  This way, you can get a more obvious look for your power-up icon.  It is a slip fit and meant to be glued together.  AS NOTED ABOVE, orientation of the pins is important.  For example, the base block for the Cat and Builder pins is the same, each is a 180 degree flip from each other.  Thus, please take care and ensure that the base pin block is in the correct orientation as compared to the icon.  

I have provided files for all of the Style 2 pin bocks; however, I have only designed Icons for the Bee, Propeller, Cat, Fire, Builder, and Ice.  I am still working on the other icon designs so stay tuned for future updates, or… fire up your mad CAD skills and upload some awesome remixes!

Other Notes:

Mario's existing Lego buttons will snap onto this model and the feet have been designed to still affix to Lego boards and pieces.

For contest purposes, I have also included the Basic Lego Mario pants as a direct replacement. I added little nubs on the inside in the even that someone wished to modify the pants and make them into a different power-up pants instead.

Here is the side by side of my pants (sorry I've only printed the DUPER pants for obvious reasons!) to a borrowed set of original Mario Pants.