How to build a cardboard animal mask with ears
There's something quietly wonderful about pulling a cereal box from the recycling bin and turning it into a koala or a kookaburra before smoko. Cardboard mask-making is the kind of slow, sticky-fingered project that suits a long Australian arvo, especially when the kids are bouncing off the walls during the spring school holidays. With a few basic supplies, a pair of scissors, and a bit of patience, you can craft a wearable piece of theatre that costs almost nothing and lives on in the dress-up box long after the glitter has been swept up.
This guide walks you through the whole process, from sketching the base shape to popping on the elastic. You'll find a quick comparison of popular Aussie animal choices, a materials list, and a few decorating tricks to make each mask feel like its own character. Whether you're prepping for a Book Week parade, a backyard birthday party, or a rainy weekend in Melbourne, this project is forgiving, fun, and ready to adapt.
Materials and tools you probably already have
The beauty of a cardboard animal mask is that almost everything you need is already sitting in the kitchen drawer or stacked next to the kerbside bin. Most Australian households run through a box of Weet-Bix every fortnight, which means sturdy brown cardboard is rarely in short supply. Add a few extras from the stationery cupboard and you're ready to roll.
If you need to top up, a quick trip to Kmart or the craft aisle at Bunnings Warehouse will sort the rest. Aussie crafters tend to keep things simple, so don't feel you need specialist gear. The aim is a sturdy, comfortable mask that takes paint well and bends slightly without cracking.
| Animal | Ear style | Difficulty | Main paint colours |
|---|---|---|---|
| Koala | Round, fuzzy | Easy | Grey, white, black |
| Kangaroo | Tall, pointed | Medium | Tan, cream, brown |
| Wombat | Small, rounded | Easy | Brown, beige, black |
| Kookaburra | Short, compact | Medium | Brown, white, blue |
| Bilby | Long, upright | Medium | Grey, pink, white |
This table helps you pick a critter that matches the materials on hand. If you're working with a flat panel from a tissue box, a wombat or bilby works beautifully. Got a taller, sturdier offcut from the side of a fridge box? A kangaroo mask lets you stretch those impressive ears to full height.
Cutting out the mask base
Start by measuring across the bridge of the wearer's nose to the centre of their forehead, then add three centimetres on each side for the eye area. Trace this gently onto the cardboard with a pencil, never a pen, as ink can bleed through the paint later. A side plate or a saucer makes a perfect curve for the top of the mask, while a round glass or mug works well for tracing the eye holes.
Cut slowly with sharp scissors, and if you're making this with younger kids, an easy trick is to score the cardboard first with a craft knife held by an adult. Pop down to your local council library during the school holidays and you'll often find free mask-making sessions where librarians pass around templates. Otherwise, fold the cardboard gently, press along the fold, then cut along the crease for a clean edge.
Once the base is cut, hold it up to the face and check the eye holes line up. If they're too high, trim the bottom edge. Too low? Re-trace and start again. Cardboard is forgiving, and a spare cereal box gives you a second chance without a trip to the shops.
Adding the animal ears
The ears are where the personality really lives. Cut two identical ear shapes from a separate piece of cardboard, then think about how each animal wears them. A koala's ears sit high and round, almost touching at the top of the head. A kangaroo's ears are long and tapered, often slightly curved at the tip. A bilby's ears stand tall with a paler inner ear, which means a smaller scrap of pink paper glued to the centre adds instant character.
For a sturdier ear that holds its shape, glue two identical shapes back-to-back, sandwiching a short length of florist wire between them. This lets you bend the ears into a jaunty angle. If you've grabbed some foam sheets from Bunnings, layer thin foam over the cardboard for a softer, more costume-like finish.
Quick ear shapes to try:
- Round and stubby, like a wombat or koala
- Tall and pointed, like a kangaroo, bilby or fox
- Small and triangular, like a kookaburra or quoll
- Floppy and droopy, for a bunny that always charms the dress-up box
Glue the ears firmly to the top edge of the mask base, then reinforce with a strip of masking tape across the join. Let the glue dry fully before moving on. About twenty minutes is usually enough, though a warm Aussie day speeds things up nicely.
Painting and decorating
Acrylic paint is the go-to for cardboard because it covers well, dries quickly, and doesn't warp the paper the way water-heavy paints can. Pour a little onto a paper plate palette and work in thin coats. For animal faces with a lot of detail, like the banded eye stripe of a kookaburra, use a small round brush and steady hands. Big flat areas, like a wombat's back, take a wide brush and a sweeping motion.
Australian kids love a bit of flair, so don't be afraid to add the unexpected. A few dabs of glue and some glitter from the party drawer turns a plain bilby into a fairy-witch bilby for a dress-up box that's part story-time, part sparkles. Coloured paper, sequins, fabric scraps, and even a bit of wool for a lion's mane all stick well with PVA glue.
If you want a furry finish, brush a thin layer of PVA over the painted mask, then sprinkle on a little shredded coloured paper towel. It dries with a surprisingly soft texture and gives the mask a tactile quality that suits a hand-crafted toy. Let everything dry flat on the bench overnight before adding elastic.
Comfort, elastic and dress-up play
A mask that pinches or slips is a mask that ends up on the floor. Measure a length of thin elastic to fit comfortably around the back of the head, then thread it through two small holes punched near the temples of the mask. Knot it firmly on the inside, and trim any excess. If the elastic feels too tight, slip a small cardboard tube bead onto each side to act as a slider. This trick is popular in Aussie primary schools for adjustable dress-up gear.
For extra comfort, line the inside edges with a strip of soft felt or an old tea towel. It cushions the cardboard against the forehead and stops the paint from rubbing off onto the skin. A little dab of PVA holds the fabric in place.
When the mask is finished, the fun really begins. Pair it with a dressing gown for a quick wombat costume, or throw on a green t-shirt and a tail for an instant bilby. If your little maker loves a bigger build, this cardboard rocket costume pairs beautifully with an animal mask for a full cast of characters in the dress-up box.
Small extras that complete the costume:
- A tail cut from cardboard or felt, pinned to a t-shirt
- Face paint details around the eyes and cheeks
- A simple headband for creatures with antlers or horns
- A cardboard paw or two for the hands
The best part of a homemade mask is the stories that grow up alongside it. Once the elastic is tied and the ears are perky, kids carry their cardboard critter into the backyard for hours of imaginary play. Tuck it safely in the dress-up box when the day winds down, and it'll be back out the very next arvo for another adventure.