Henchmen Mask Kit

This is a quick tutorial on how to assemble our Venture Brothers Henchmen mask kit, which you can buy here( if it’s in stock).

This is what you will get in the mail, but depending on what my plastic supplier has available it may be white(or the angry eye version, the build method is the same):

Now we can start by assembling our tools. This is what I used and suggest, but it is not the end all be all.
1:Sandpaper: Both high and low grit. At least 400 grit, preferably 600 for the high.
2:Dremel  with thin sanding drum: This will help you quickly sand out the eyes and clean up the edges of the mask. You can put the mask together without one, but it will take much longer.
3:Paint: I used Krylon Plastic Fusion yellow and Now wagon red. (black primer & black acrylic paint if you have a white mask)
4:Low temp hot glue gun: Make sure its LOW temp! You do not want to warp the plastic or burn your fingers. The cheap little ones work just fine
5: Scissors: Kinda self explanatory
6:Elastic band: So you can wear it!
Ok, now we can start! The first thing we need to do is get the mask into the proper shape. This means sanding, and lots of it
The Dremel really helps out here, just be careful with it. It’s very easy to take off too much material. So take your time and get the eyes and the edges cleaned up and smoothed out. You will also want to take your high grit sandpaper and go over the whole mask, this will help the paint adhere. I know the Plastic Fusion brand paint says that you don’t have to sand, but don’t believe them! After you are done with your sanding, clean off your mask. Either use an air gun to blow it off or rinse it in some water and let it dry. Before you move on really take a close look at it. You do not want to get it all painted up and then realize that you needed to even out an edge. Now if your mask is white plastic you will want to first lay down a layer of black primer. This will help the yellow look “right” without having to spray multiple coats. Get the eye mesh out as well. You do not have to prep it at all, just paint it. Remember to follow all the directions on the spray paint can! This can really affect how the  finish looks. If possible hang your mask from one of the eye holes for painting. I didn’t not paint the backside of the mask because we will be hot gluing things to it.  Let the paint dry overnight. We will be handling the mask a lot so you want the paint to be fully cured before we move on.
All right, at the start of day to your pieces should look like this ^. Now before we glue in the eye mesh there is one detail that we have to do first. To really make the eyes “pop” we are going so make the tiny inner edge of the eye hole black.

If the mask that you got is black plastic, all you need to do is very carefully sand off any paint that on that edge. If you have a white mask you can carefully paint the edge with some acrylic paint. Let that dry completely before moving on.

We are ready to start gluing. Plug in your glue gun and while it is heating up see if you need to trim any of the eye mesh. We want as much overlap for gluing as possible, so don’t trim anything unless it hangs over an edge. To start you are going to put a bead of hot glue down along the top ridge of the eye hole. I used colored hot glue to make it easier to see.

Press the top of the mesh down into the glue. You want to see the glue worked into the weave. The safe way to do this is to use a pen or a stick to push the mesh down, and that’s how I’m telling you to do it. I used my fingers, but that’s because I’m dumb.
After you have let the glue cool down on the top, flip your mask over and press your thumb gently into the center of the eye mesh. You want the mesh to have a gentle bulge out of the eye hole. That, with the black line we added earlier  will give the eyes a more 3d look.
Once you have the mesh in the right place you can start gluing it down. Really work the glue into the mesh, and make sure to overlap the edge. Work it in small sections and let the glue cool before moving on.
Once you have both eyes glued in you can add your elastic. Start from the middle edge of the eye and lay a bead of glue out towards the side of the mask. Quickly press one side of your elastic into the glue and let it cool. After it has cooled, top coat the elastic with more glue, overlapping the edges. Once that has cooled down, hold the mask up and pull the other side of the elastic around and touch it to the side of the opposite eye. Adjust how much you have to pull for comfort and then cut off any excess. Repeat the the gluing process and you are all finished! I hope that was helpful, and feel free to post pics of your finished masks in the comments.

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