Kaolin clay is commonly used to create Dan Masks. Kaolin clay is found in South and Western Africa, and is a white, alumina-silicate. At its most basic natural composition, Kaolin clay is powder. Mixed with water, the powder will turn to clay and can be shaped into the Dan Mask. The shape of the Dan Mask face can be created manually or can be manipulated on a polystyrene foam or wooden mannequin face. Kaolin clay can dry in hot air or in a kiln.
Dan Masks have also been made in bronze. Many Dan Masks that are aged and sought after by collectors have a medium brown to dark brown patina (coating) over the original bronze material. To work with bronze and create a Dan Mask like the original ones, one can purchase bronze metal clay from a specialty art store or supplier. Bronze metal clay will turn to solid bronze when fired in a kiln. It can be formed by oiled hands, and can be textured using any type of rubber stamp. Bronze metal clay can be rolled and laid over an oiled face model (non-human) to create the shape of a Dan Mask. Eyes, nose and mouth can be cut from the bronze metal clay. Before firing this material in the kiln, it must be dried.
The Dan tribe considers the forest to be their spiritual realm and sometimes carved their masks out of wood. For the amateur wood carver, the best tools for carving wood into a mask can be purchased from a wood carving supplier. Look for a beginner's wood carving kit that contains roughing and detail blades, chisels, gauges and a slip stone. Sandpaper is needed to help shape and smooth the wood. The best wood for making a Dan Mask is teak, palm or timber woods indigenous to Liberia, where the Dan tribe first began. An adzee is the tool Dans and Africans use to carve their wooden masks. It has a thin, arched blade.
After the base of the Dan Mask is created, accessories and colors can be added to complete an authentic-looking Dan Mask. Feathers and rope were used by Dan tribe members as hair. Beads were added to the feathers and rope to accessorize the hair. Brown paint or patina is used to create the face or skin shade. Cowrie shells are indigenous to the West and South coasts of Africa, and are commonly used as decorations on the Dan Masks. Rope can be braided or separated and combed out for hair and beards.