DIY Mascot Halloween Costume Masks

Here are the basics to making any mascot head. Each head costs about $4 in Fabric and then whatever extras you want to add.

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Step 1: Paper Mache

I buy the large punch balloons and paper mache the whole thing with about 4 layers. Let dry overnight. Pop the balloon and cut the hole in the bottom for your head.

Step 2: Making the Head Durable

Cut the mouth however you want it. This will be what you see through. You can also cut the eyes too if you want more vision. I use cardboard strips around the bottom and around the mouth/ eyes to make it stronger.

Step 3: Fabric

Measure around the head and the height. cut fabric needed and then cut it into 4 pieces.. Top to bottom. cut each strip to a point at one end. sew all your sides to each other all the way through your points and slip over the head. cut a slit for the mouth or eyes and fold back and glue on the inside. At this time if you want to add some stuffing to bulk up cheeks or brows you can and then glue the bottom to the inside as well.
Now you're ready to start creating your character.

Step 4: Adding the Extras

I use see through fabric for the mouth and or eyes. glued to the inside. You can add wigs, hats or anything else. I sometimes use Styrofoam balls for noses ( painted with acrylic paints).

Monster from the muppets I didn't use almuch fabric. i bought regular yarn and hot glued it.

I use foam for the eyes or teeth. Any additional piece like ears or snouts i sew like making a pocket, stuffed and hand sew on.

The clown I used an actual clown wig and cut it into pieces. His teeth are foam with some red paint on them.

The red clown with the blue nose.... I covered in brown fabric and then with the red. There are large eyes cut, no mouth but the red fabric is see through.

The monkey has eyes and a mouth cut and covered in sheer fabric. The snout is structured with cardboard, stuffed and then hand sewn on.

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    10 Discussions


    Question 2 months ago on Step 1

    How large ? 12 inch 16 inch or 18 inch ? 16 is the most common


    2 years ago

    I really wanted to do this to make a dinosaur head for myself...but I'm unsure of how to make the snout as it would be pretty long and I'm worried that nothing would be strong enough to hold it onto the face. I thought maybe somehow I could papier mache the snout on WHILE I'm papier macheing the head...but I dunno how I'd manage that...maybe I could do the head first, let it dry and then papier mache on the snout? Any suggestions?


    4 years ago on Introduction

    Hi, I am about to make the animal mask. I am a drummer and play for my Youth band at church. We are having to make a unique costume for a contest and I wanted to animal. This is a great idea and is easy to follow, one question, how did you make the mouth? It seems complicated but I want to know before I start (im paper mâché ing tomorrow). Thank you for the help!

    5 replies

    I scored a piece of cardboard and folded it in half for the whole mouth. I glued them on the inside of the head so there wasn't a ledge at all. They are both kind of angled.

    I cut a large hole where the mouth will go and constructed the mouth from cardboard, hot glued it in place, and painted it. Hope this helps. Thanks.

    It does amazingly haha. Im doing my second leyer of mâché right now. I have one more question about the mouth. Did you angle the cardboard On the bottom half of his mouth upward Then connected it with another board on the top?


    5 years ago

    Super cool way to mask up.
    I like the red Muppets monster.

    1 reply

    Reply 5 years ago

    Thank you so much...he's my favorite too. I might add a spiked collar and chain to him.