Bane is one of the most intimidating villains in recent superhero movie history. If you want to create your own Bane costume for Halloween or another event, you will need a Bane mask of your own. The masks available in the market can be very expensive, so if you are on a budget, it is best to make your own mask.
Part 1 of 3: Create the mouthpiece
Step 1. Find a respirator mask that fits your mouth
It is preferable to wear a respirator mask with filters on the side and a mouthpiece on the front. They can be found in most hardware stores or army surplus stores.
Make sure any professional grade mask you buy has removable side filters
Step 2. Convert an airsoft mask if you are on a tighter budget
You can use half an "airsoft" mask that only covers your mouth, or a full "airsoft" mask without the goggle part. These can be found in sports equipment stores and can be cheaper than professional respirator masks.
Step 3. Use a particulate respirator if you are on a very low budget
If you can't find a full respirator mask, or if your budget doesn't allow it, you can purchase a simple dust mask, also called a particulate respirator, instead. These masks do not have mouthpieces or filters and are generally simple white masks that fit over the mouth.
If possible, look for one that comes with a thick strap rather than one that uses a bungee cord
Step 4. Remove any unnecessary pieces
Twist or unscrew the filters on the side of the respirator. The mouthpiece of the mask can remain if it is flat enough, but if it sticks out more than 2.5 cm (1 inch), you will need to remove it as well.
- If you are using a full airsoft mask, remove the part of the goggles and cut away any plastic that is on the glass of the goggles.
- Use a sharp knife or saw to remove this plastic.
- Sand any sharp edges with an electric sander to avoid injuring yourself when you put on the mask.
Step 5. Cut a hole in the mask if necessary
Most professional respirators and airsoft masks have a small hole where the mouthpiece is located, in which case, no cut is necessary. However, if you are wearing a dust mask, you will need to cut a hole 1 to 2 inches (2.5 to 5.1 cm) wide, just above the point where the mouth will be.
To get a better idea of where the mouthpiece should be, place the dust mask on your face and use a pencil to mark where your mouth is on the mask. Remove the mask and cut the hole with scissors or a utility knife
Step 6. Place thin tubes over the mouth area
Cut four 3-1 / 2-inch (9-cm) pieces of pipe that are 1/2-inch thick. Use hot glue to glue these four pieces together at regular intervals along the top of the nozzle. The opposite should be glued on top of the nose piece of the mask.
- If you don't have a mouthpiece on the mask, put the mask on your face and lightly mark a line where your upper lip is with a pencil. Arrange the pieces of tube along this line at regular intervals.
- Thin tubes like these can be found at a hardware store.
- For an easier and cheaper alternative, you can use flexible straws instead of tubes. Cut, fold and shape the straws before gluing.
- You can use fabric glue or jewelry glue instead of hot glue if this is not available.
Step 7. Install thin tubes under the mouth area
Cut another four 3 1/2 inches (9 cm) tubes that are 1/2-inch thick. Use hot glue to bond them evenly along the bottom of the nozzle section. The other end of each piece of tubing should be glued to the chin part of the mask.
- If you don't have a mouthpiece on the mask, put the mask on and lightly mark the line where your lower lip is with a pencil. Order the pieces of pipe along this line evenly.
- As suggested before, you can use bent straws as an alternative to tubes.
Step 8. Install thin tubes over the cheeks
Cut two 4 1/2 inches (11 cm) pieces of 1/2 inch (1 cm) pipe and two 7 1/2 inches (19 cm) pieces of 1/2 inch thick pipe. Start with the smallest pieces:
- Glue the smaller pieces directly next to the end pieces of the tube over the mouth. The bottom end of these two new pieces of tubing should be hot glued to the sides of the nozzle.
- If your mask does not have a mouthpiece, then glue the other end midway between the rows of tubes for the upper and lower mouths.
- Use hot glue to attach the larger pieces you just glued to the top end. Glue the bottom end of these last pieces of tube next to the bottom end of the bottom mouth tube row.
- As mentioned above, you can use bent straws as an alternative to tubes.
- Let everything dry completely so the glue seal doesn't break.
Part 2 of 3: Add the head piece
Step 1. Cover the side straps of the mask with leather
Cut a strip of feather, or other sturdy black fabric, so that it is twice as wide as the width of the strips and just as long. Use hot glue or fabric glue to coat the side straps with this material, hiding the seam or ends of the material on the inside of the strap.
- If you don't have wide straps on your mask and you only have a thin elastic cord, go out and buy a 2.5 inch thick black elastic band
- Cut this piece of elastic to match the length of the elastic cord and glue it to the mask on top of the cord.
- Keep the edges of this band on the inside of the mask to hide them.
Step 2. Measure the top of your head
Use a soft tape measure to determine the distance from the tip of your nose to the base of the skull. Also measure the width of the bridge of your nose at both the top and bottom.
- For a more precise fit, put on the mouthpiece portion of the mask before proceeding.
- Measure from the top of this mouthpiece, over your face and head, and to the point where the strap meets the back of your head.
Step 3. Cut a piece of flexible foam to match the measurement
Look for soft black foam that is no more than half an inch thick. Use fabric scissors to cut a strip of foam that matches the measurement for the top of your head, plus 1 inch (2.5 cm) to allow overlap for gluing.
Step 4. Trim the strip to the width of your nose
To start with, the foam should be as thick as the widest part of your nose. Next, you will need to contour the shape of the strip to better fit your nose.
Step 5. Adjust the strip according to the shape of your nose
At one end of the foam, narrow where the top bridge of your nose will be. If necessary, temporarily place the foam over your head and mark the area that you will need to cut out with a pencil.
Step 6. Cut a piece of synthetic leather
Place the foam on another piece of black leatherette and trace the shape onto the other material. Use fabric scissors to cut out the shape of the synthetic leather.
If you don't have synthetic leather, choose another strong and durable black fabric
Step 7. Attach the synthetic leather to the foam
Apply fine lines of hot glue to the back of the synthetic leather and press the foam into place over the glue. Make sure the edges line up as evenly as possible.
Step 8. Attach the foam to the mouthpiece
The narrow part of the nozzle needs to be glued with the hot glue just above the top of the nose of the mask. The widest and even section from the back of the foam strip should be glued onto the strip covered with the synthetic leather on the back.
- Make sure the strap goes in front of, above and behind the head in a straight line.
- Glue the edges of the foam head to the inside of the mouthpiece, hiding them from view.
Part 3 of 3: Finalize the details
Step 1. Place single thin tubes on the sides of the top of the mouthpiece
Cut two 1/2-inch pieces of tubing that match your measurement for the top of your head. These pieces should be the same length as the strip of fabric that covers the front, top, and back of the head.
- Glue these pieces of tube along the edges of the top piece, placing one tube on each edge.
- Note: these pieces of tubing are too long to substitute for flexible plastic straws. If you can't find tubes, you can skip this step or use leatherette covered foam tubes instead of the tubes.
Step 2. Glue small bolts near the head piece tubing
Take the small studs and glue them in pairs along the top of the head piece. Each bolt should be on the inside of the tubes along the edge of the head piece.
- You should have between five and eight pairs of bolts, or between 10 and 16 individual bolts, total.
- Separate the pairs into equal intervals.
- If you don't have bolts, you can use belt cleats or similar metal objects instead.
Step 3. Paint the mask black
Bane's mouthpiece has an intimidating dark black color. For a consistent, uniform look, use spray paint that is labeled to work on a variety of materials (metal, plastic, fabric) and spray the entire mask black.
- Depending on where you paint it, you can put a layer of newspaper or a cloth rag on before painting.
- Let the mask dry for several hours in a warm place with low humidity.
Step 4. Paint the mouth tubes silver, if desired
For a slightly more authentic look, you can use silver metallic paint and a paintbrush to paint the tube of the mask silver. This is not strictly necessary, but it can add more realism to the final skin.
- Check the label to make sure the paint is safe to use on plastic.
- Let the paint dry.
Step 5. Put on the mask
Bane's mask is now complete. Put it on and see how it looks. If you notice that the straps are loose or tight, make adjustments as necessary by trimming or gluing additional fabric to lengthen the straps.