Step 9: Cut the Mouth

You will now cut the mouth!

The mouth is up to you

I freehand drew the mouth lightly with a pencil and made it as even a smile as I could.

Make sure that the mouth cuts out the drill holes that marks where their eyes are.

The reason:
The person will be seeing through the mouth... But people won't see the person's eyes because there will be some fabric in the way!

To cut the mouth:
Get out your dremel (if you don't know what a dremel is look at the pic on this page) and attach a round blade to it.


Cut out the mouth by cutting with the dremel along the light pencil lines.

Once the mouth is cut out, you are done with the dremel!

If you have some rough edges on the lines where you cut the mouth, sand it down until is looks good.
" Great costume! You should submit it to http://hauntedknoll.org "
Me and my wife as Mr & Mrs Jack...
can i buy the male one. please message macisback1@gmail.com with info and ur price. 30 or below and exact replica shown in picture <br />
wow!! how did u make urs? it looks really good!
Similar to the instructable, but used a beach ball and so-flo fabric starch for the paper mache (dries much harder, and with less layers) The important thing to remember, that I think alot of other Jack Heads had forgotten, is scale. The hat has to be in proportion to the rest of the Head. I did not use a foam cone for the hat and nose, rather I fashioned one out of newspaper and paper mache'd it. This way you can get proper scale. <br>These are the 2nd &amp; 3rd Jack Heads I have Made, Mrs. Jack was fun, got lots of comments about her, just added a flower and eye lashes (all made out of paper mache) and gave her a pink hat...
Your heads look great. I made one about 15 years ago. Lasted a couple of years. Then turned it in to a Pumpkin for a yard decoration. What I wanted to know is how many layers did you use using the So-Flo Fabric Starch (so love that stuff)? Did you put anything in it to make it stay in place while on your head? As far as the eyes go, did you use something for them so you could see? My daughter is wanting to make one for this Halloween and the techniques are better now then they were 15 years ago,, lol...any and all suggestions are greatly appreciated.
I used 3 layers of paper, specifically brown grocery bags. If your using newspaper, it will probably take 5 or more. To make it stay in place on my head, I actually used styrofoam that I just made a simple 5 sided box out of and hot glued it into the head (sculpted the front and back a little to be as comfortable as possible). The eyes were just painted on, it's the mouth that is cut out. I found the field of vision through the mouth much better than through the eyes, and the head sits more accurately; not so far down on the shoulders. I found this plastic mesh from the craft store (I think it's used for yarn needle work, found over by the yarn and sewing section) It comes in alot of different colors, and you can see through it with no problem. I hope this helps a little, good luck...
@tkaiser1 - did u use just the Sta-Flo as the mix or did you throw in flour (as the bottle of Sta-Flo suggests)? I've been working on this a couple of days now (2.5 layers in) but I still feel that the layers are a bit flexible. Any feedback truly appreciated!
I used the Sta-flo straight from the bottle, didn't know they had instructions on the bottle, guess I had never noticed... I would assume adding the flour would make it more pastie since flour is a thickening agent. You really have to go by feel on these things, the stronger the better...
Nice job with your heads. What did you use to shape the cone for the hat? I would like mine to be as accurate as yours
they look really good! i dont think i could make something that nice..lol
i did this in less than a week and it cost me less than 5 dollars. thanks very much. it was a tad bit different though but you were still great help
hey id love to buy that. for like 20 bucks. please send me a email to macisback1@gmail.com name ur price and tell me when or if you can do this <br />
how did u do it my good man?
I made this in 3 days... I used a cheesehead i have from being a packers fan to keep it secure on my head! i followed these instructions to make it pretty closely! Did some stuff different though! Me and my friends were the Fast Food Mafia.
Took my son &quot;Jack&quot; to Jack in the Box and they let me take pictures behind the counter.
does anyone have a made one i can buy from them? i live in los angeles...<br><br>also, what kind of ball are you using that you can puncture it and it still holds up and are u cutting a hole out of the bottom for it? hows it working exactly?
Hey! Great costume idea!<br>My boyfriend made one sorta following your instructions. He made the head from paper mache using Sta Flo liquid starch from Wal Mart (It works perfectly as paper mache mix). He used a smaller ball, a yellow construction paper hat, and used cheese cloth for the eyes instead of the mouth. He also used a sharpie red marker to freehand the mouth and a sharpie blue marker to color the cheese cloth. We got some great feedback on it. :)
making one right now, did it in three nights so it wont be as amazing as previous ones and yours, but still pretty awsome.
I didnt boil the flour is that a bad thing? lol
Made my 7th grade self's day. <br> <br>I used a balloon to shape mine, which worked pretty well, and made the mouth, hat, and nose out of construction paper. <br> <br>Of course the nose has since fallen off, and the head now sits ominously in a window sill to scare new comers and salesmen - quite well if I do say so myself.
how do you see <br>
All of the employees at Jack In The Box should wear these!
I got first place at a costume contest last year with this, and won an ipod nano :)
OH&nbsp;NO, Mr. Bill!<br />
With a little adaptation this could be turned into The<a href="http://fallout.wikia.com/wiki/Pint-Sized_Slasher_Gear"> Pint-Sized Slasher</a> mask from Fallout 3.<br />
May i take your order<br /> <br />
id like 25 tacos, 5 extra large drinks, and 80 cheeseburgers.<br />
ill have the same but make the cheeseburgers doubles.
&nbsp;nice the hat should be shorter though
well done!<br />
&nbsp;Could you show a pic of the bottom looking in to the head...... I'm wondering how big the hole you put your head in should be.
very cool! i would make this but i dont have the time or the patience! looks wicked cool :) i never would have thought of this!
It does take quite a while! Thx for looking!
I've actually thought of making this before, but I think your Instructable has given me the...courage?... to help me do it! Thank you!
sure XD
I'm got make this. Then in the middle of the year next year just wear it to school. Or go Halloweening in July...not sure which yet.
Instead of the batter's helmet, you could use an old bike helmet, then you would have the straps to hold it on your head better
yeah, i made it , i used a giant balloon from zurchers, and in stead ok making the entire mouth the hole, i just made a simple rectangle, and in stead of using foam for the hat, i got some poster board and made a cone for his hat, and i got another for the rim of his hat. i thought mine was pretty convincing when i was at a zoo for a costume contest and mothers were having me hold their babies for pictures (and im 14) it looks pretty nice, and as soon as i get the pictures, ill put them up (and i won 1st place in the costume contest)
there is only one person i know that can pull this off lol hey look me up on my space
im making this costume right now, but for the head im using one of those punching balloons
that some fly shit
very cool instructable! (favorited)

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