Instructables
Picture of Borderlands Psycho Mask

This years halloween costume. The mask is made from air dry clay and a cpu fan. There is a layer of plasti-dip on the top to strengthen and give a "distressed look". There is a hidden toggle switch under the chin that to control the interior lights. I'd like to apologies for the lack of photos, I hadn't intended to do a step by step but a few people asked.

Materials

  • Plain white plastic face mask
  • Crayola Model Magic Clay 8oz pack
  • Swimming goggles
  • 40mm computer fan
  • 2 Leather Belts
  • Plasti-dip Spray can
  • Plastic lid
  • 5V Blue Leds, battery clip and wires

Tools

  • Soldering Iron
  • Super Glue
  • Scalpel

Nothing difficult here guys. I'm not artistic and I haven't soldered since school. Just takes some patience.

 
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Step 1: Working with the clay

Picture of Working with the clay

The make or break part of this build is how well you build up the clay on the mask, so this is just a few tips and pointers of how to work with the clay. All of which were learned from this tutorial.

I first rolled small sections of the clay out using a rolling pin (read: wine bottle) until it was roughly 5mm thick. Then any piece I wanted for the mask was cut out from this "sheet" using the scalpel and a ruler. The rule was only used very roughly, as any excess or lack on the mask could easily be fixed by removing or with a bit more clay. I used my fingers for 90% of the shaping, but the few flat edges I wanted I just used the handle of the scalpel.

Each piece was laid on the mask and the edges pressed down to stick it in place. I then used the "wet finger" technique from the linked tutorial to remove any joints between pieces. I didn't bother with sandpaper, I tried it and couldn't make it work. I found I could smooth out the clay sufficiently by wetting my thumbs and sliding them across the clay, pressing softly as I went.

Be sure to work with small pieces of clay at a time. If you have a large rolled sheet it will dry out on you, this is air-dry clay after all.

KristiS129 days ago

For DanaM1 (and anybody else). I did use a plastic mask. The clay did not stick...and when it dried, it cracked in a lot of places (thick and thin areas). But, I glued the cracks with liquid nails glue (color white...paintable) and I'm hoping that the glue in the cracks will adhere the clay to the mask. The cracks actually give a really awesome distressed look that I couldn't have planned better. I'm adding plasti-dip spray today. Hoping that will help stick the clay to the plastic mask too.

Eireannach (author)  KristiS129 days ago

That's an awesome tip! I might do some repairs to mine now!

DanaM11 month ago

did you have any problems with the clay sticking to the mask? Someone said it doesn't stick to plastic as well as a paper mask, but it seems like that would be too hard to mold to, plus the shape wouldn't be as smooth.

Eireannach (author)  DanaM11 month ago
I didn't have any problems with the clay sticking but now a year later I can see the clay starting to peel away.

Nice job! planing on going to comic con as a Psycho. This will help give me idea on ways to go about the mask part. thanks!

pheenix427 months ago

STRIP THE FLESH!! SALT THE WOUND!!

Sarrx7 months ago

hey, what type of plastidip did you use?

siavash_memar8 months ago
nice work ,and fun to do ,tnx
andrea biffi9 months ago

very good!

dupes8889 months ago
Ha i love this game and mask im almost done with bl2 uvht
eyouel9 months ago
Awesome
Aleator7779 months ago

Nice work! Not too complicated and looks easy to do.