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.


  • 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


  • Soldering Iron
  • Super Glue
  • Scalpel

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

Step 1: 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.

Do you take commissions?
<p>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. </p>
<p>That's an awesome tip! I might do some repairs to mine now!</p>
<p>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. </p>
I didn't have any problems with the clay sticking but now a year later I can see the clay starting to peel away.
<p>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! </p>
<p>hey, what type of plastidip did you use?</p>
nice work ,and fun to do ,tnx
<p>very good!</p>
Ha i love this game and mask im almost done with bl2 uvht
<p>Nice work! Not too complicated and looks easy to do.</p>

About This Instructable


554 favorites

More by Eireannach: Cheap Steampunk Chess Set Game Boy Hard Drive Borderlands Psycho Mask
Add instructable to: