- 1). Bend two pieces of heavy gauge wire into the shape you want for the ram horns. Use 18 inches of wire for each horn for an adult costume and 12 inches for a child. Make one curve to create simple horns or several bends to create complex horns. If necessary, use a vice grip to hold the wire and pliers to help you bend it. Otherwise, use your hands. This creates the armatures for the horns. Wrap aluminum foil around the wire to create bulk for the large ram horns.
- 2). Tear pieces of newspaper into 1-by-6 inch strips. Dip the strips into a bowl of liquid starch. Let the strips sit for 30 seconds each. Then, pass the strips between your thumb and index finger to wipe away excess moisture.
- 3). Wrap the strips around the horn armatures. Add additional strips to the armature until the wires and aluminum foil are completely covered and the horns are as thick as you want them. Make the curved tips of the horns thicker than the end that would be against the ram's head. Set the horns aside to dry for 24 to 48 hours.
- 4). Paint the surface of the horns using tan or light grey acrylic paint. Let the horns dry overnight. Paint lines around the circumference of the horns using acrylic paint two to three shades darker than the base color. This creates the ridges on the horns. Let the paint dry overnight.
- 5). Attach the horns to a 1-inch wide plastic headband using hot glue. Apply the glue to the end that goes against the ram's head. Press the horns against the headband where you want the horns attached. Let the glue dry 5 to 10 minutes. Tear additional strips of newspaper. Dip them into liquid starch. Use the strips to wrap around the headband where the horns touch it. Wrap them around the base of the horn and the headband, two to three times, to further secure them. Leave it all to dry for 24 hours.
- 6). Cut two 3-inch triangles from a piece of brown felt. Squeeze the bottom of each triangle together. Hot glue the triangle at the base to create the ear shape. Hot glue the ears to either side of the headband near the horns.
- 7). Wear a brown long sleeve shirt, brown pants, brown shoes and brown socks.
- 8). Paint your face with brown face paint to finish the look.
Source...