DIY Horn Urethane Foam Construction

Use a real set of horns as inspiration.

Add a blast of creativity to any costuming project with a set of high-density urethane foam horns. Using real horns poses danger to the person wearing the costume or anyone nearby. One accident can cause serious injury. High-density urethane foam -- or egg crate foam -- is soft, flexible and a safe alternative. Cover your foam pieces with a paper mace coating to provide an ideal surface for the application of acrylic paint.

Things You'll Need

• High-density urethane foam
• Measuring tape
• Standard chalk
• Scissors
• 2 medium-size plastic bowls
• White glue
• 5 cups water
• 1 cup flour
• Pot
• 1-by-4-inch paper towel strips (multiple)
• Acrylic paint
• Paintbrush

Instructions

1. Draw a 3-by-8-inch horn onto a piece of high-density urethane foam with standard chalk. Make the horn into the shape of a crescent.

2. Cut out the shape of the foam horn along the chalk lines with scissors.

3. Place the foam horn atop a second piece of high-density urethane foam. Trace and remove the first horn. Cut out the shape of the second foam horn along the chalk lines.

4. Flip a medium-size bowl so the bottom side is facing up. Bond one foam horn to the right side of the bowl with white glue. Bond the second horn to the left side of the bowl with white glue. Allow 30 minutes for the glue to dry fully.

5. Boil 5 cups water and 1 cup flour in a pot for 3 minutes. Allow 5 minutes for the mixture to cool. Pour the mix into a second medium-size bowl.

6. Soak a 1-by-4-inch paper towel strip in the mixture. Press the strip onto one of the horns. Continue until both horns and the bowl are covered in a layer of paper towel. Allow 3 hours for the horns and bowl to dry.

7. Coat the horns and bowl with acrylic paint. Allow 2 hours for the horns to dry before handling or wearing.

References

• DLTK Kids: How to Paper Mache