This DIY was created for my 2012 Halloween FAUN costume. I began this project by researching other horn Instructables on this website and YouTube my main inspiration comes from : WndrRt's Craft tutorial on YouTube.
I chose to make Ram's horns because they are Large scale.
What you will need :
(2) Wire hangers - Free
(1) Wire cutters/pliers - Free
(1) long wooden dial - Walmart .50cents
(1) Jewelry wire - Walmart $1.30
(1) low temp glue gun - Walmart $5.00
(1) exacto knife (Box cutter) - Free
(2) packages of low temp glue - Walmart $3.50
(1) pipe insulation foam - Hopme Depot $2.00
Scrap material ( I used a old pair of hospital scrub pants) - Free
(1) roll of wax paper - Free
(5) packages of foam cord - Home Depot $3.48 each
(1) roll of crepe paper or streamer paper - Free
(1) paper mache' kit ( I used flour and water) - Free
(1) tube of Acrylic paint - Walmart $3.00
(1) package of cheap sponge brushes - $1.00
(1) headband - Free
(1) ducktape - Free
If you see Free beside the item, it just means I had the product at home and just used what I had. :)
Step 1: Making the Mold
I knew i would need a large base for this so i chose to use my ironing board because it came with holes already in it and its extremely sturdy. I began with straightening two wire hangers with pliers. I then put the two wires in two holes of the ironing board and twisted them at the base. Once the two wires are secure I began to bend the wires one at a time into the appropriate shape that i felt looked best.
From there I took a 40 cent wooden dial that i purchased from Walmart and made (8) 2 inch mini dials. This would make sure my mold stayed sturdy. Once the 2' dials are hot glued in place, I took an extremely thin wire (typically used for making jewelry) and zig zagged it from the bottom base to the tip of the wires and closed both wires with a rubber band.
Step 2: Adding Insulation
Once your beginning mold has been formed its now time to make the horn appear thick and solid. The pipe insulation comes as a long 6ft tube, so you will need to cut it in half. I took one of the half's of the foam and cut it into (6) random sized pieces. I have already tried to modify the entire form with the Ram horn twist, so the pieces can only be fitted to size as you place them to the sides of the form.
The hot glue will begin to slightly burn the insulation on the inside, this will allow for it to fit snugly around the edges of the mold. This is a good thing! After all the insulation has been laid on each side of the mold, double check to make sure you have covered the very tip of the the horn, you don't want any wire exposure.
Step 3: Covering With Cloth
Its time to cover your insulated mold with cloth. For this step I needed a thin cotton cloth to cover the "Bones" of the project. Adding this step will make the mold smooth and be a skin for your horn. I used old scrub pants that were not important and cut them into large rectangle panels. I did measure to make sure each rectangle would reach completely around the form.
If using hot glue YOUR FINGERS WILL GET BURNED! This step was very painful because you want to pull the fabric taught over the form and the only way to achieve that is to hold down the areas where you have applied glue. I was using Hot glue, but for you... I suggest using an aresol spray glue such as Super 77 which can be found at Walmart for $4.88 in the craft section.
Step 4: Complete Cloth Covering
Be sure to completely cover the Form!
Step 5: Wax Paper Essentials
This wax paper step is simply to keep your horn mold from being destroyed by the hot glue in the following step. For that reason I wrapped my mold twice, you may not want to.
Now that your horn form is smooth and covered with a thin cotton cloth, take wax baking paper and cut it into 3' wide strips. I would start at the pointy end of your form because as I learned, by now your form has a rounded tip. This way you can cover the tip of the form and still continue with a smooth layer as you hot glue the wax paper the rest of the way down. Again when using hot glue be careful of your fingers.
Step 6: Foam Rope
This product took me forever to find. So i thought to feature it so you would know exactly what to look for. Its called Baker Rod and is found at Home Depot!
Step 7: Wrapped in Foam
This step is to make the Ridges on the horn. It is Super important not to skip this step because you want your horn to be air light. This foam rope is essentially your Horn. Everything leading up to this point was only to form a mold. For this step I took my wire cutters and removed the Horn from my ironing board base so I could twirl the cord around easier.
Once the foam cord (Backer Rod) is taken out of its package you will see that it is a very long cord of foam. Take the Backer Rod and cut it maybe about 4ft long and take a dot of hot glue and start at the Base of the horn mold and press the Backer Rod to it. The wax paper does not adhere to hot glue very well, so you do not have to worry about the Backer Rod sticking to the wax paper very much. Begin wrapping the cord around the form. As you go up lay strips of glue on the Backer rod, it will melt the foam slightly, again this is a good thing because it will create a seal in between each ridge. Continue wrapping until you get the end of the horn.
Step 8: Crepe Paper
Before I began wrapping the foam mold in crepe paper, I wanted to take the Foam molded horn off of the mold base. This should have been SUPER easy because of the wax paper, but as we all know, It just can't be that easy. So, simple solution...cut it off. CAREFULLY. You may find a better way to do this, but I simply made a incision along the inside bend and pried the foam mold away. This only worked because I used enough hot glue between the ridges and made the incision very straight by using my exact o knife. So, it only took a few slides of hot glue along the incision to put the horn back the exact way it was on the base mold.
Now that you have a foam horn, you will notice that its lost a little of its twisted ram shape, this is easily solved by taking two more wire hangers, straightening them out and then bending them into the same shape as your original base horn mold. A little hot glue at the bottom and the tip will secure it inside. Once you have your shape the way you originally wanted it, begin placing the crepe paper around the horn.
I chose to forgo the hot glue for this, it was just unnecessary, simple scotch tape will do. Just be sure to pull the crepe paper as taught as you can with out tearing it.
Step 9: Completed Crepe Horn
Just a glance at how the horn should look completed with crepe paper.
From this point you would return to your original Horn mold that is still wrapped in wax paper and begin the process of wrapping it in foam Backer rod, then removing it from the form and wrapping it in crepe paper to make a second horn.
Step 10: 2 Crepe Horns
What both horns should look like when completely covered in crepe paper.
Step 11: Triming
Once both horns are made you will be able to test where they should sit on your head and from there be able to trim down the excess.
Step 12: Headband
The Biggest issue with having large scale items on your head is how to get them to stay! Fortunately these horns are only Foam, Glue and paper so they are hollow and super light.
With a sharpy I marked where the head band would would need to sit on my head in order for the horns to be level with one another. I then took my Exacto knife and cut away all the foam until it was a shape of a C, This would allow the head band to fit with out any problem. I applied glue to the horn foam Not the head band. This way i would place the horns exactly where I needed. I did this with out help, so it was a shot in the dark trying to make sure both sides would be level over my shoulders.
Step 13: Test
They sat perfectly where I wanted them!
Step 14: Ducktape
Just to ensure the glue didn't fail to ad-hear while wearing the horns , I used duck tape as security.
Step 15: Paper Mache'
To cover all imperfections and to make a sturdy outer shell I chose to paper mache' the horns. Being that I had everything in my kitchen to do this, I gathered up some paper towels, flour, and a big bowl filled with a little water and mixed well. You only need to cut the paper towel into thin inch wide strips maybe like 4 inches long. Messy but it works.
Step 16: Paint
I chose a dark paint to match my hooves, ears and Dred falls that I made by hand, but a spay paint or a mix of colors would definitely look very nice. I needed to go over the edge around the headband another time in this pic, but I was happy with it. Being that you will be starting with a white horn, any color will show up vibrant. A blank canvas is always best.
Step 17: Matching Hooves
Another Piece of the Faun! My Hooves!
I made these from a pair of heels, an old pirate hat that had a gold brim and scraps of fur that I used to make my Satyr legs. Thanks for checking out my Instructable!