How to Make Your Own Styrofoam Head

Written by ehow contributor
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A Styrofoam head is a must if you like to make hats or period clothing. Because it is helpful to design hats to fit a head, it's helpful to have a block, or a head form, to put your hats on. It's also helpful to have a block so you can test out your design as you make the hat and catch any details before your design or the hat is finalized. You probably have most of the necessary pieces around the house to make your Styrofoam head, allowing you to put more money toward feathers, fabric and other important hat-making supplies.

Skill level:
Moderately Easy

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Things you need

  • Measuring tape
  • Pen and paper
  • White glue
  • Sharp knife

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  1. 1

    Measure your head. The important measurements are from beneath the ear on one side and across the head to beneath the ear on the other side; around your head at the point just below your ears; and from the back of your head at the point where it joins the neck to over the head and below your chin. Write all these measurements down on a piece of paper. You will use them to create your Styrofoam head.

  2. 2

    Collect some pieces of Styrofoam. You can use the Styrofoam that's used as packing material to ship breakable items. Collect enough Styrofoam that's taller and wider than your head and glue all the pieces together with white glue. Let the glue set over night.

  3. 3

    Using a sharp knife, start cutting away the Styrofoam so it matches the measurements of your head. Take your time and remove a little bit at a time rather than taking off big chunks at once. It is far easier to remove Styrofoam than to put it back once you've removed too much.

  4. 4

    Add detail to your Styrofoam head. It is up to you how detailed you wish to be. You can just have the general shapes of the eyes or detail the Styrofoam head so you have outlines for the pupil and iris on the eyes, nostrils, lips and more.

  5. 5

    Finish the Styrofoam head by smoothing the surface with sandpaper so any unintentionally rough edges are gone.

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