Here’s what you’ll need:

- Cintra PVC foamboard(3mm thick)

- Paper Clay(not pictured)

- Hot glue gun

- Metallic paint (I used Folk Art Metallic Bright Red, Folk Art Metallic Silver Sterling, and Folk Art Metallic Inca Gold)

- Sand paper (Medium)

- X-acto blade

- Scrap paper and board

- Cheap plain mask or mold (Optional - I found it made shaping the cintra MUCH easier)

- Elastic band

Step 1: The Pattern

Draw out your main mask piece on paper. Make it long enough to cover your ears. Make perfect circles where your ears will be. Fold and then cut for symmetry.

Trace it out on the cintra.  Also draw out 8 larger circles(same size as the ends of your main mask piece) and 4 smaller circles. Cut everything out with the x-acto blade.

I'm working on the winger. and this would be perfect with it. Thanks!
I love these! I love tf2 also. But i am to lazy to go to the store and actually work, y'now?
I really love to see more hats from u making the gunslinger would be cool
Cool can't wait til u do it!
Hey can u make the robot version of bonk boy
Oooh, definitely looks tempting! would like be a pretty similar technique, just more geometric shapes. I might have to at some point. :)
That is actually quite sexy.
Very cool. I don't really play TF2 but I like this. I might try to do something similar with this technique.

About This Instructable


234 favorites


Bio: I am a horror illustrator and a mask maker. I also eat a sizable amount more toast than the average human being. Impressive, I know ... More »
More by KatieLawter: Regular Show's High Five Ghost Costume Blighted Beak - Plague Doctor Mask How to Make a TF2 Bonk Boy Mask
Add instructable to: