Hey guys! I made these horns for a Jedi costume, but they can easily be transferred to a Mando as well.
To start, go to a craft store like Michaels's and get some Sculpy. It's kind of like a bakeable plasticine type material. It comes in a variety of colours. The one I chose is kind of a pale bone colour, though I've seen excellent Zabrak horns with darker colours too.
Break small pieces of Sculpy off the main brick. It help to have a good knife when carving, and perhaps some clay modelling tools if you have them. Start sculpting your horns. Make a variety, but don't make them too big. If the horns are too large, you'll have a hard time keeping them on your head. Also, remember to maintain symmetry of horns. They don't need to be an exact mirror, but they should be a close match. Your horns also shouldn't be perfectly smooth. Use your knife or a tool to give them a grainy or striated texture, like Darth Maul has. For inspiration, try looking at antlers.
Once your horns are sculpted, ensure there's a slight con cavity to the side that will stick to your head. Place them on a baking sheet and bake as per the instructions on the package.
After allowing your horns to dry, paint them using either a dry brush or colour wash technique to give them some added dimension and show off the detail.
When you're ready to put your horns on, shave your head.
. You can attach the horns using theatrical glue. I use Pro's Aide, which works like rubber cement.
Facial Tattoo tutorial to be added.
