Nightmare Before Christmas Barrel Prop Tutorial

Here is a tutorial on how to make a life size Barrel from the movie. He is one of the three trick-or-treater kids /Oogie's henchmen: Lock, Shock & Barrel.

Supplies Needed:

-Pink insulation foam (2" thick)

-Carving supplies
-Cheap pool noodles (Dollar Tree/.99 Store)

-1 Yard grey fleece fabric 

1 Sheet white felt (8.5"x 11")

-2 plastic Easter eggs

-Acrylic paints

-Hot glue

-Plastic toy lollipop (Dollar Tree toy section)

*Optional: Alternate version uses a foam-core poster board (Dollar Tree).

(Detailed tutorial corresponds with the picture tutorial above)

Face Mask:

1.  Cut a 9.5" diameter disc out of insulation foam. I used a plate as a template .

2. Use a knife or carving tools to shave off the harsh edges, to create a dome shape .

3. Use a fine Grit sand paper to sand and smooth the disc shape .

4. Using a photo for reference, trace the features of Barrel's mask lightly with a pencil.

5. Use an exacto blade to carve and cut out the features of the mask (eyes, nose and mouth).

6. Take the bottom (wider end) of two plastic Easter eggs. Twist and press them into the mask's eye sockets.

7. Prime : Use a grey primer to coat the entire mask.

8. Paint : Using acrylic paints, paint the mask white . Add black accents to the eye sockets, nose and mouth. Add off-white color to the teeth and eyeballs. 

9.  Dip a nice pencil eraser into some black paint to make a perfect stamp for the eye pupils. Optional : Add a acrylic gloss varnish to the eyeballs for "wet", life-like eyes. The Mask is done .

Hands, feet and Lollipop:

10. Feet : Cut two horseshoe shapes out of insulation foam. Notch out two triangle shapes out of each. Using an exacto blade , shave off the harsh edges, for a rounder, softer top. Using a fine grit sand paper, sand and smooth the feet. Prime and then paint the feet using a green color.

Hands : I carved the hands out of insulation foam. Then primed and painted the hands using a green color. (I forgot to take progress photos of this, sorry).

11. Lollipop : I found a plastic lollipop toy in the toy section of Dollar Tree . Try to find one there . Re-paint it with black and red acrylic paints. (If you can't find one , make your own out of a thin insulation foam disc and a wooden dowel stick)

Body Assembly: Here is the tricky part to explain...

12. Cut Barrels body shape out of a solid piece of insulation foam. The insulation foam body continues up behind the bottom half of the mask to support it. There are no photos shown of this. (*Alternate version uses a foam-core poster board (Dollar Tree). I did use a foam-core poster board as a backing for the majority of his body. Due to the fact that I only had scraps of insulation foam left. I wanted to use up my scraps. I pieced them together and secured them to the foam-core . Ideally, I would have cut his body out of one solid piece of insulation foam.) Slice cheap pool noodles in half vertically, use them for Barrel's arms and legs. Secure all the pieces together. I happened to use screws, but you could use glue or caulk . Side note : Hot glue will melt insulation foam and not stick...

Clothing/Costume:

13. Wrap body with grey fleece fabric. Measure , Cut and fit material onto body. Secure it with glue or pins. Hot glue works well on the fleece . (One yard was only $2.99 at Joanne's Fabrics with coupon).

Head/Hair & Ears:

14. Hair : Since Barrel wears a mask, his real head and face are supposed to be behind the mask. I used a segment of a pool noodle to make the top of his head. I bent it in to a horseshoe shape and screwed it to the back of the mask. (Use short screws so you don't poke through the front of the mask and ruin it). Cut and tear the surface of the noodle with scissor cuts to make the illusion of his claymation hair. 

Ears : Cut the ears out of insulation foam.  Secure them to the back/sides of the mask with caulk or short screws.

15. Paint the hair with a black primer, and then a dry brushing of olive and army greens (use photo for reference). Paint the ears with white acrylic paint, use a grey/black to shadow the inside of the ear.

Bones:

16. Measure and draw the bone shapes for Barrel's costume . Use a black Sharpie marker on white felt. Cut them out with scissors. Hot glue them onto the clothing. (Use a photo for size and placement reference)

Now you should be done ...Please comment if you have any questions.  Good Luck...