Make a sketch of your mask design on a sheet of paper. If you’re not confident about your artistic skills or you’re just after accuracy, use a preprinted pattern or a picture of the mask.
Transfer the design to your piece of wood. Attach a sheet of carbon paper on top of your sketch design or picture. Lay both sheets over the exterior surface of the wood and tape the edges of the paper onto the edges of the wooden block. Trace the mask pattern using a pen or pencil so that the outline is copied onto the wood. Check that your design transferred by detaching a corner of the paper. Repeat the trace if necessary and remove tape when you’re satisfied with the transfer.
Using a chisel or wood tools, begin cutting into the wood to create your design. Cut wood away to create depressions. Mold the inside of the mask by chipping away at wood to create a hollowed out area where a face can fit.
Cut out appropriate shapes to represent the eyes, nose, nostrils, eyebrows and mouth. Use chisels or a small power saw to start out the holes and carefully enlarge them as you cut to meet your design specs.
Adorn and embellish the mask with symbolic etchings. Use heavy tools to cut out pattern outlines. Refine your work with the finer tools in your wood tool set. File etched edges until smooth or rub sandpaper over the surfaces to finish.
Paint decorative symbols or warrior colors. If you want to be true to a particular mask, review photos and pictures of traditional ones to be sure you make accurate markings and make appropriate use of color.
Smooth out the internal surface of the mask with sandpaper. Rub sandpaper until the mask is free of sharp or irregular areas and is comfortable to wear. Test the wear and comfort by moving the mask into various positions on your face to be sure no spots were missed.
Drill or cut holes into the sides of the mask so you can attach string, ropes or wires to hold the mask into place. Add holes at the top if desired. Thread the rope through the holes and tie a knot on the backside for security.