Cartoon Violence (The Costume)

This is an update on a the Teddy Bear Assassin costume I made last year (this can also be viewed on Instructables). I had a little more time this year to improve the mask and create a more durable base. These instructions will also work if you want to build an inexpensive bear head and costume, or mascot. This is a moderately difficult costume, and cost around 25 dollars for all of the supplies.

If you want to view an easier way to make a similar costume, see the previously posted Teddy Bear Assassin costume.

Things you will need: 

- 2 wire hangers
- regular and needle nose pliers
- duct tape
- 1 bag pollyfill
-  hot glue gun and bag of glue sticks
- 1 regular kitchen sponge and 1 large kitchen sponge
- 1 pair children's black knit gloves
- dark colored felt
- light colored felt
- about a yard of fake fur fabric
- black permanent marker
- black quilting thread and sewing needle
- 2 ping pong balls
- small piece of cardboard

optional (for mallet)
- oatmeal container or similar cylindrical shaped object
- large sheet of cardboard (at least 18 inches in length)
- black duct tape

Step 1 Building the Base

The first step to any of these masks is to build your foundation. This will work for any type of full-head mask that you want to make. The idea is to get a shape that will fit on your head and then work around that. I don't make masks to cover my face in part because I wear glasses and also because I don't to constantly have to remove my mask to talk or eat (I wore this to a costume party).

I found out last year that a simple cardboard base doesn't tend to hold up, so this year my goal was durability. This mask started with a wire frame made from wire hangers shaped to fit around and along the top of my head. There are two parts (see the attached photo), one that fits right on my head, and the other extended beyond the height of my head. This is because I wanted the mask to be much higher on top of my head. The top of that second, higher piece represents the top of the bear head. That is how high the mask will be.

To create this wire frame, begin by unraveling one of the hangers and shaping it in a sort of oval form. It should be big enough to fit around your forehead, but leave a little slack. The second part runs from the forehead to the back of your head. The third piece runs from the top of one ear along the top of the head to top of the other ear. Attach the second and third piece to the first piece, and you should have something like a half dome shape. Because you're working with a wire hanger, it is sometimes hard to perfectly cut and shape the pieces with the pliers, so wrap the connecting points with duct tape so you don't cut yourself.

When you finish the half dome, add the longer strips over the top to form the top of the mask head. I added the piece of sponge in between for comfort because once you complete the costume, the bear head tends to add a little weight between the top piece and the part resting on your head. In the end, it really wasn't necessary because when you add the Polyfill padding, it rests gently against your head and is comfortable.