The Blue Spirit

Picture of the fully assembled mask and swords.

For Halloween 2021, I dressed up as The Blue Spirit from Avatar: The Last Airbender. It took a couple of years to make, partly due to COVID, partly due to needing to learn so many new things at once. I had made other costumes in the past with paper mache, but this time I was working with foam for the mask.

I learned a lot by watching folks on YouTube, like Evil Ted Smith, who has a ton of tutorial videos on making all types of masks and helmets. The mask is actually mostly constructed out of floor mats (a common cheap, first-timer recommendation). There are multiple levels of finish on the mask to attempt to smooth out small imperfections, but I suspect had I started with true EVA foam, I wouldn't have needed as much effort here.

The Blue Spirit isn't the Blue Spirit without his swords. I really wanted to make the "one sword that splits into two", and created two mirrored swords held together with magnets. They're thin plywood, cut and sanded into shape. Using some leather strips, paint and vinyl, I was able to get a pretty decent match to drawings I found online. There's a sheath as well, which holds the swords together, and matches a bit of the sword's guard.

Paired with a store bought "ninja uniform", we did a little photoshoot. I don't think the cats particularly liked me in the mask! I'm planning on building a piece of wall art to hang the mask and swords on, but haven't started that yet. Overall, it was a pretty fun project, and I love to look up from my desk at work to see the mask on display with my other masks.

A clay model of a face, with an extended chin section.

Very basic foam mask form, no eyes or anything. Just a full face covering.

The mask has small circular eye holes now, and the typical Blue Spirit ears and crown.

In addition to the ears and crown, there is a very thick eyebrow-like foam piece laying on top.

The eyebrow has been shaved down to match the real contours of the mask instead of a blocky form. Also, thin eye outlines are added. All pieces are pinned on.

The chin-line was way too square and was tapered down.

With the eyebrow and eyes pinned on, a mustache piece is cut out and pinned on either side of the mask.

Similar to the eyebrow, the mustache is tapered down to blend into the mask.

Using some white EVA foam, a nose and teeth are cut out.

Overtop the teeth are two fang-like teeth, also white EVA foam.

Using Fine Finish, a paint-like finish on top of the foam, I could smooth out the texture and sand it down.

First coat of PlastiDip being sprayed on. A lot of foam color is still showing through.

Second coat of PlastiDip. The mask is now all white.

Using masking tape, the white details are covered to paint the rest blue.

After multiple times back and forth with blue and white paint, the painted mask is finished.

Layering chiffon, my eyes are hidden behind the mask.

Two crossed swords, cut out of quarter inch plywood.

The swords mirrored, and sanded to 'point', as if it were a single sword.

Crossed swords again, but with a plywood guard.

The swords mirrored, side to side, highlighting the matching guards.

Using silver spray paint, the swords hang with the blades painted. The guard and hilt aren't finished.

A fairly chunky sword sheath, also made from plywood, painted black.

Two swords, with magnetics for securing side-to-side. The hilts are leather wrapped. The guards and sheath are wrapped in gold vinyl.

A close up of the leather wrapped hilt and wooden pommel.

Another close up of the swords, this time length-wise.

An outdoor shot, wearing the mask and brandishing the swords as one.

An indoor shot wearing the mask, sheath and 'ninja' uniform. I am holding up a 'peace' sign.

A crouching pose, still wearing the full outfit (minus socks and shoes :o).

An iPhone screenshot. 'Face Obstructed, try removing anything that may be covering your face'. I'm wearing the mask.

Our cat, Kaoru, is shying away from me while wearing the mask, and swords.

Published on Aug 27, 2023