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To make wearable demon horns, carve a matching pair from flexible upholstery foam, texture them with paper-towel strips and liquid latex, paint the dried surface, then mount them on a plastic headband. The method comes from Breanna Cooke’s Make tutorial, published October 20, 2015; its stated project time is 38 hours, with no breakdown of active work versus drying time.
Gather the materials and tools
Make lists flexible polyurethane upholstery foam (1 ft × 1 ft), paper, hot glue, liquid or mask latex, about ten paper towels or tissue paper, a plastic hairband, and acrylic paint. You will also need a marker, small scissors, a box cutter, a hot-glue gun, and paint brushes: two medium and one small. Make says latex can be found at costume, theatre, or mold-making supply stores.
Shape a matching pair of foam horns
Make and transfer a pattern
- Draw the desired horn silhouette on paper and cut it out.
- Trace the pattern onto flexible foam. If the foam is too thin for the shape, cut matching layers and glue them together.
Carve the forms
- Trim away small amounts with scissors or a box cutter, gradually tapering and shaping the horn rather than cutting deeply at once.
- Use the first horn as a guide while shaping the second so the pair is similar in size and profile.
- Cut a trench into the base of each horn for the headband. Angle the base if you want the horns to tilt backward.
Add the paper-towel texture
- Tear paper towels into strips. For raised ridges, roll an edge of a strip before applying it.
- Brush liquid latex onto a section of foam, place a strip over it, then brush more latex across the strip to hold it down.
- Continue layering strips over the foam until the surface has the texture you want. Let the latex dry before painting.
Dry latex may remain tacky. Make suggests dusting the surface with baby powder to reduce tackiness before handling or painting.
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Paint the horns
Use acrylic paint. Start with a light base coat, add darker colors, then dry-brush to create a rough gradient and bring out the raised texture. Let the paint dry before attaching or wearing the horns.
Attach the horns to a headband
Fill each base trench with hot glue or contact cement, then press the plastic hairband into the trench and hold it in place as the adhesive sets. For a more secure fit, especially for performance, Make suggests adding small hair combs at the horn bases or along the sides of the band. The tutorial also mentions a helmet or another headpiece as possible mounting options, but provides fewer attachment details for those setups.
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How this method differs from a glue-and-paper form
This build uses a carved, flexible-foam core, liquid latex to bind the paper-towel surface, and a wearable headband mount. Adafruit’s motion-reactive LED devil-horns instructions instead describe dipping paper-towel strips in a glue mixture over a form. That is a distinct construction for an LED project, not evidence that the glue approach can be substituted directly for latex on carved foam.
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Make labels the project difficulty “Easy” and lists a time required of 38 hours. The page does not say how much of that estimate is hands-on work and how much is drying time. The tutorial presents the horns as modifiable for different costume characters, but does not establish a universal size, durability, or performance guarantee.
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