Here's how I did it.
Step 1: Supplies
- 1-2 Champagne Corks
- Thick aluminium wire
- Card or thick paper
- Brown fur or hair
- Standard steel wire
- UHU glue
- Craft knife
- Needle nosed pliers
- Super/Krazy glue
- Brown, black, and orange Sharpies
- Styrofoam cutter
- Wire cutters or metal cutting scissors
- Fine black permanent marker
- Orange acrylic/poster paint
- Black and white, or grey paint
- Orange pen
- Hot glue (most other glues will melt styrofoam)
- Transparent plastic foil (from packaging)
- Yellow pen
Step 2: The Head
Use a permanent black marker to draw the eyes, nose, and mouth.
I did the hair before the rest of the face so I wouldn't position the beard and the eyebrows too high, but it wouldn't make a difference if you did it last.
For the hair, I glued wads of brown fur onto the top and sides of the cork, leaving a space where the ear should be. Then I trimmed it all down to the appropriate length and filled in gaps where you could see the cork with a brown Sharpie.
Now draw on thick brown eyebrows as shown above. To draw the beard, plan it out with a soft pencil, then go over it with the brown Sharpie.
Finally, for the glasses, draw the frame out on a piece of transparent plastic foil (from some packaging) and cut it out. Make sure that it fits the face. Don't attach the glasses yet though, because they might get ruined during the other steps.
Step 3: Hazard Suit
To make it using styrofoam, hot glue pieces around the entire bottom of the cork, making sure it's fitted as tightly on the cork as possible. Then use a styrofoam cutter to cut away at it until it is the correct shape. Use a craft knife for details. Try to use a sharp knife, as blunt blades will tear the styrofoam, creating jagged edges.
The shape of the styrofoam in the end should look similar to mine above. Leave a slanted flat part on the front, but slant it slightly less than I did.
Step 4: Painting
Step 5: Crowbar
Finally, use permanent markers (Sharpies worked well) to give the crowbar its painted texture. I used red first and then added the black while the red was still wet.
Once it's dry, attach the crowbar to the side of the cork by pinning it down with a short piece of wire. Now you can also add the glasses. I did this with some Krazy glue (only apply glue to the nose and under the hair).