How to Create an Affordable Mascot Head





Introduction: How to Create an Affordable Mascot Head

You will learn how to create a mascot head on a limited budget.

Step 1: Gather Materials

Buy foam board at hardware store. For this project I used two 2x8 sheets of Owens-Corning InsulPink.

Step 2: Cut Rough Shapes

Cut the board into ovals, or circles, or whatever the shape of your mascot head. There are many ways to cut the board such as razor blade, keyhole saw, and jig saw. Any type of saw will make a mess. The easiest, cleanest and fastest way is with a hot knife. The store bought hot knives are expensive and flimsy. I made my own following the instructions at instructables (Hot-Knife-for-Plastic-Cutting!). Instead of hammering the soldering tip, I bought a three inch long brass screw and hammered/filed it flat. It worked great. As you cut the layers try to get the rough shape of the head. IMPORTANT  if the piece is too big it is easy to make it smaller, if the piece is too small it is very hard to make it bigger. When you cut the first pieces, make them bigger than you think you need them. Another tip is to number the pieces, label the top and bottom. That way it is easy to put them back together in the correct order.

Step 3: Cut Out Room for Your Head

One-by-one, cut out room for your head. When you do this the first time, make it tight on your head. You can always cut more later. If you cut too much in this step you have to discard the piece and redo it. In these pictures I cut a space much larger than my head. I did this to make room for a construction helmet (you will see in a later step). I also cut space for ventilation fans which you will want if you plan to wear it for four or more hours without taking it off.

Step 4: Assemble Core

Assemble the core by attaching the middle sections together. WARNING  most glue will melt the foam. Fortunately, plain old Elmers glue works great. I also used 3 drywall screws to hold the pieces together as the glue dries. Makes sure you allow at least 24 hours for the glue to dry. If you want you can install a construction helmet (as a very nice head support) and ventilation fans. For ventilation fans I used old PC fans connected to 9 volt batteries (sorry I dont have a picture but you can see the holes for the fans). Make sure that it fits and is comfortable before going to final assembly.

Step 5: Final Assembly

Attach the remaining pieces. Cut holes for the eyes, nose and mouth (if applicable). Use sandpaper to smooth out the shape. Glue felt or any fabric on the outside to complete the head. Thick fabric will help hide rough spots and imperfections. If possible, paint the head with a latex paint which is the same color as the fabric (especially if you are using a thin fabric). Add ears, whiskers, nose to make it an incredible mascot head.

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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!


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!

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Thank you for the picture. That is awesome!

Thanks for the amazing tips on the mascot head. I am very pleased with my Gizmo!

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Awesome Gizmo.

Oops! Here is the Stitch costume we made with your directions

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Awesome. Thanks for the posting. It makes we want to post more stuff on Instructables.


How would you measure the circumferences of the foam if you were making a perfect circle?

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Hello! I was wondering what the thickness is on the foam board you used in this project. I managed to find several 2'x2' boards with one-inch thickness; is this the thickness what you were working with?

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I used 1.5 inch thick board.

I used elmers glue to hold the pink layers together but I do not recommend it.
The glue takes months to dry. I recommend the special glue for foam.
I also used 3 inch long screws to hold the layers together.

I used spray glue to hold the fabric to the outside. I don't remember the brand. It worked well.

can someone make a mask exactly like this except a polar bear (only thing different make white ears and make white on the outside of the eyes instead of black )


and then i will buy it

Hi I don't really understand step 2 and 3 I'm looking to make a circle head (panda) but I don't understand do you cut a bunch of circles or and them connect them , please can someone help me thanks.

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Hi LisaT162,
imagine that you are taking the panda head and slicing it into layers with a giant knife. And each slice is the same thickness as the pink foam board.
When I made my Hello Kitty head, my slices were vertical. But I see that somebody else posted a brutus the buckeye head and his slices were horizontal.
The middle slices would be the biggest. and the end slices would be the smallest.

If you look at the pictures in my instructable, you can see different views of the slices.