How-To: Make an Uncle Sam Mask

This Uncle Sam pattern can be used to create a mask or a patriotic decoration. Simply download the pattern as a PDF, gather up some foam and get started! Instructions are in the PDF and available with step by step photos below.

Tools List:

HWFF Hot Knife (any size)
HWFF Foam Fusion or StyroGoo Glue
Black Fine Point Marker
Scissors
Paint Brushes

Materials List:

22??? x 14??? x 1??? EPS Foam Sheet
22??? x 14??? x 1/2??? EPS Foam Sheet
Acrylic Paint, Suggested Colors Include: Red, White, Blue, Peach
Cottonballs
Glitter (Optional), Suggested Colors Include: Red, Silver, Blue
Googly Eyes (Optional)
Paint Stick/Large Popsicle Stick (Optional)

Directions:

Adults – help kids when using the Hot Wire tools

There are two ways you can make Uncle Sam – he can either be a mask or just a decoration, so plan on cutting out the eye-holes if you would like to make a mask, or leave them intact and paint on the eyes or add googly eyes to make him a décor item.

To begin, download the pattern here and print it out. The pattern will print on three sheets of letter-sized paper and when assembled, should look like this:

Tape or pin the pattern onto the foam and poke holes around the edge of the pattern with a pen or the HWFF Engraver. If you would like to reuse the pattern, you may cut out the pattern pieces with scissors and transfer the patterns to the foam by tracing around each piece using a fine point marker. The main portion of the pattern (Uncle Sam’s face and hat) will be cut out of 1″ foam and the accent pieces (the hat band, mustache, beard and hair) will be cut out of 1/2″ foam.

Using the HWFF Hot Knife, cut out the pieces. If making a mask, cut out the eye holes and if desired, use the knife’s tip to create details like the nose and mouth. You could also use a marker to add a nose, mouth and eyebrows once Uncle Sam has been painted.

Paint the pieces as desired with acrylic paints and set aside to dry completely. If desired, apply glitter and set aside to dry completely.

Assemble the pieces and glue together with the HWFF Foam Fusion or StyroGoo glue. Stack the hair, mustache, beard and hat band onto the main face portion to add depth. Set aside to dry completely.

Once everything is dry, stretch out some cotton balls and glue them to the hair, beard and mustache and let dry. If desired, you may add a paint stick or large Popsicle stick to make the mask easier to hold.