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.

More photos at Imgur.

via Make