Picture of How to Create an Affordable Mascot Head
You will learn how to create a mascot head on a limited budget.

Step 1: Gather Materials

Picture of Gather Materials
Buy foam board at hardware store. For this project I used two 2x8 sheets of Owens-Corning InsulPink.
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cubesnail made it!10 months ago

Did it with my friends. (I'm the one in blue). Pretty proud of it, thanks so much!

edgukated (author)  cubesnail10 months ago
That turned out awesome!!!
Thanks for sharing the pictures
Can you please tell me about the ventilation,
I m planning to keep it more at least four hours so please show me how it's done the fans thank you very much.
edgukated (author)  Eniogarcia1 month ago

Hi Eniogarcia,

If you look at the pictures in Step 3 you will see that the two middle pieces have extra material removed. These form 2 holes from the head space up to the top of the head where the ears go.

I took 2 cooling fans from an old pc and put one in each hole. They were 24 volt fans so I had to use two 12 volt batteries in succession for each fan. But you can buy 12 volt fans on the internet.

I wired it so that one fan sucks air out and the other blows air in, and I gave each fan an on off switch.

All of that is crammed inside the head by carving out some extra space. (no picture shows that)

The picture attached to this comment was taken from the top of the head looking down into one of the holes. You can see the ear on the left hand side of the picture. If you look real close into the hole you will see the PC cooling fan.

2015-07-11 07.43.32.jpg
Mrkittywolf made it!8 months ago

Finished my happy costume using these instructions


What about any other tips/lessons you learnt from doing that costume? Can I know the measurements of the mascot head? And why did you hollow out the mouth and what material replaced it?


And thank you very much in advance for your reply

Can you please tell me how you did the ears, and how you kept it standing. Also, for the head, you cut circles and only cut out the middle parts of the circle right?

I am planning to do a happy mascot cosplay as well.

edgukated (author)  Mrkittywolf 8 months ago

That is awesome. Thanks for the pictures.

Bucknutt made it!9 months ago

brutus!!! Thanks for the help

edgukated (author)  Bucknutt8 months ago

Great work. Thanks for sharing.

aliao11 year ago

how about this one? oisk mascot

edgukated (author)  aliao110 months ago

That is awesome

Thanks for the tips. I used a white Styrofoam sheet, cheaper but messier. And I jammed a batting helmet in there to make it stay on better. Go cats!
jten293 years ago
I noticed other people on this forum were talking about creating an owl head...this is intended to be a gift for someone..Followed your steps, and I'm pretty satisfied with the end result...(definitely buying a soldering iron if I attempt to make another, you're right... cutting with a saw creates a huge mess.) Thanks for the advice!
edgukated (author)  jten293 years ago
Thank you for the picture. That is awesome!
cbundy3 years ago
Thanks for the amazing tips on the mascot head. I am very pleased with my Gizmo!
edgukated (author)  cbundy3 years ago
Awesome Gizmo.
mamamick3 years ago
Oops! Here is the Stitch costume we made with your directions
edgukated (author)  mamamick3 years ago
Awesome. Thanks for the posting. It makes we want to post more stuff on Instructables.

RouRou_19783 months ago

I want to make disney Mc stuffins head with a fan, pleeeeeeeeeeeease help :"O

edgukated (author)  RouRou_19783 months ago

What sort of help do you need?

scourgeo4 months ago

I was wondering how I could possibly do one of scourge the bloodclan warrior cat

could you please help me??

edgukated (author)  scourgeo4 months ago


a Scourge the Bloodclan Warrior head should be fairly straight forward if you
follow the steps in my Instructable listing.

will need a little bit of artistic skill.

you start, do not worry about the ears, or hair, or whiskers, or fur. Those are all things that you can add after
you have the basic head built.

you aren’t sure where to start, I would recommend that you get a piece of
cardboard and cut out a shape that includes Scourge’s nose (which would
probably be about the same level as your nose).
Once you have a cardboard shape that you like, copy it onto the foam and
cut the foam. From there you can add
layers above and below.

you have any specific questions, please feel free to ask.


Hi , i m trying to create a miky mouse mascot head.Did anyone knows about? ThaNKS!

Essicaj8 months ago
I'm looking to make something like this... Less boobalicious. Main focus is the panda head.
This seems like it would be the easiest way to get the shape that I'd need.
Just have a few questions... Is it really uncomfortable and hot? How well can you breathe and see out of it?
edgukated (author)  Essicaj8 months ago

Hi Essicaj,

It is as comfortable or uncomfortable as you make it. I used a construction hardhat as the main support. I wear it 30-60 minutes at a time and some times 4-5 hours a day. Foam is softer but it also retains heat.

It can get hot, that is why I built fans in mine. With the fans it isn't bad.

Mine is very hard to see out. Only two small holes. With your panda head you could make the eye area out of black see through cloth, so you would have great visibility.


Essicaj edgukated8 months ago
Awesome thank you so much!
I hadn't even thought of making the black part to see out of . Good idea!!
edgukated (author) 8 months ago

Update, here is the same Hello Kitty head as a borg.

Mawtees10 months ago

What sort of foam should I use? Here in Perth, we only have Clark Rubber.

edgukated (author)  Mawtees10 months ago

In Perth Australia go to Home Hardware Building Centre and ask for Owen's Corning Ship Lap Foam Insulation F200 Item number 2719-121

mkarr11 year ago
What were the dimensions of your largest foam pieces?
chrischango2 years ago
hi um i was just asking ......i was going to make a perry the platyus costume but i dont know how to make the bill in front can you please help.
bwhelton3 years ago
I want to attempt making the rabbit helmet from the anime "doubt" but the rabbit has big puffy cheeks in the front and I had planned to just cut the shapes into the foam board like more of a pear shape and add on to the cheeks so they continue, but I also wondered if you had any pointers or advice to make it easier?
I included an image of the doubt rabbit head
Neko-Otaku3 years ago
I love the first picture, aparantly Hello Kitty goes to Ouran High School, is Hello Kitty part of the Host Club?
edgukated (author)  Neko-Otaku3 years ago
She does in my version of reality :)
I love your version of reality :D I wish I could go there
This seems like it'd be very useful for a Rabbit Doubt cosplay I'm planning. Thanks for posting this! I poked around my local Lowe's for solid foam insulation sheets, but didn't find any. I'll try again tomorrow, and maybe this time actually ask someone for help.
edgukated (author)  TeenDreamSequence3 years ago
Keep trying. The foam board is common and I've seen it at every hardware store I've ever visited.
tmwtcfno3 years ago
Oh also what would you recommend for making a metallic, smooth look for, say, a helmet?
edgukated (author)  tmwtcfno3 years ago
Metal is always a challenge.

For starters, you could use actual metal, but if has any rounded characteristics then you will need an english wheel to do a really good job. Most people don't have or can afford an english wheel.

Whenever I work with real metal I buy flashing from the roofing section of the local hardware store. It is thin, flexible, and affordable.

However, I have used metal looking spray paint. Rustoleum makes several types and they work very well (especially from far away).

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