foam mask costume | An Original Outlaw

How to make a realistic Green Ninjago Costume- My 5 year old son wanted to be the Green Ninjago for Halloween this year. We couldn’t find one that looked like a REAL Ninjago. So, I decided to make one for him. Here are the steps. I took about 8 hours to make (a few hours an evening, over a weeks time).

: This is a shot of what the real green Ninjago (lego ninja) looks like. I snagged from Google.

: Started with 1 inch thick foam. I added a 1.5 inch thick piece inside to “hug” his head. (there is a super cheap foam place on Franklin and 18th… Heart of Texas Foam & Fabric)

: I started the carving process

: The finished carving process. I used scissors, box cutter and carving knife. (yes, like the one I use at Thanksgiving)

: I coated the foam in wood glue/PVA

: Second coat of wood glue/PVA. This protects the foam from the resin that goes on next.

: I painted on a self leveling resin called Pour-On. I purchased it at Hobby Lobby. It makes the outside look like plastic, the paint will stick to it, and it is very light weight.

: I used a piece of plastic needle point framing for the eyes so he can see. I cut it, sprayed it yellow and used a permanent marker for the black eye balls.I used a print our for the correct dimension.

: I spray painted it green and the sheild on the top silver. I inserted the plastic needle point framing and secured it with a little hot glue. Here’s the head it is all finished!