Buy a pattern to make the body of the quad suit. Adapt the pattern to make it look like your mascot. Add wings, a tail, spines, hooves, or add to the girth, as appropriate for your mascot.
Calculate how much fabric you will need and then add 1/4 yard to each type of fabric to make sure you will have enough. Ask a clerk in the fabric store for help with these calculations and to make recommendations regarding fabric choices, if desired. Remember to buy extra fabric for the mascot's head.
Make a quad suit out of inexpensive muslin if you have made significant changes to the pattern to avoid making mistakes when cutting the fake fur. Baste the muslin quad suit together by hand. Have the wearer of the quad suit put it on and make all the body motions that he anticipates making as the team mascot. Adjust the muslin pattern as needed to allow extra room for movement and ventilation.
Use the muslin pattern when cutting the fake fur. Sew the body of the quad suit according to the directions on the pattern, adapting for the changes you have made. Ask the wearer of the quad suit to try it on, and then make any necessary changes. Add a zipper or other closures. Steam seams open, pressing the fur as lightly as possible.
Mold the chicken wire to create the form you will use to make the mascot's head. Use wire cutters to snip off excess chicken wire. Make sure that the wearer's head will fit easily through the hole at the bottom.
Shape the bottom of the head so that it rests comfortably on the wearer's shoulders. Create holes that allow the wearer to see and breathe when wearing the costume head.
Tear strips of white packing paper approximately 1 inch by 6 inches.. Pour ½ cup of glue into a bowl. Add one drop of clove oil to prevent mold. Mix water into the glue until it is the consistency of tomato soup.
Place the bottom of the form on the 1-foot by 2-foot piece of wood and hold in place with nails that have been nailed partially into the board and bent over in an L-shape. Wrap the form from top to bottom, like a mummy, creating a smooth, tight surface.
Dip strips of paper, one at a time, into the glue mixture. Apply the strips to the form in a random pattern. Press air bubbles out to create a smooth surface. After applying layers of paper strips to 1/8-inch deep, allow the form to dry thoroughly.
Add another 1/8-inch (depth) of paper mâché strips and allow it to dry thoroughly. Repeat until the head is approximately 3/8-inch thick. Dry for 12 hours in a low-humidity, air conditioned room. The mascot head should be hard to touch. If the surface of the paper mâché feels tacky, allow to dry another 12 hours or overnight.
Remove the chicken wire by putting your hand through the bottom of the head. Compress the chicken wire toward the center of the head, forming a long tube of compressed chicken wire that you will be able to remove through the hole in the head's bottom. Sand the rough areas and then paint mascot's head. Spray the painted area of the head with a clear spray finish. Add fur and other embellishments as desired. Attach the head to the quad suit using Velcro.