Remember Carl from Pixar’s Up? The elderly man becomes a reluctant adventurer in the story, and even though he’s a little curmudgeonly, he’s also sweet. Imgur user CKYKOK made a Carl mask for a costume from foam and fabric and showed the process with photos on Imgur. Essential tools inclded a ruler, scissors, a permanent marker, a glue gun, an X-acto knife, and a giant serrated knife. The first step involved planning and sketches and then CKYKOK transferred the face elements to a giant block of foam and used grid lines to ensure symmetry.
The head was then carved from foam and then covered with felt. The glasses were made from particle board.