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Welcome to the first post of my blog! I’ve started getting better about taking photos during my builds, so expect more of these in the future. I want to share my process and hopefully help some fellow makers create their own spooktacular pieces.
Now, on to the goo…
Step 1: Covering the sphere form
Papier-mâché goo, that is! Like with many of my projects, I start by covering a sphere with paper mâché (strips and paste. For some great paste recipes, check out here. For this piece, I needed something larger than usual, so I chose a beach ball as my base. I worried that the tightly wrapped layers might stick, but once everything dried, the shell popped off cleanly. Unlike a balloon, I can reuse a beach ball multiple times, which makes it a great option if you’re trying to reduce waste.
I built the first three layers with old newsprint, then switched to long strips of house-painting masking paper for the final layer. That outer layer added strength and created a rough texture—perfect for the next step: cellu-clay (paper mâché clay).

Step 2: Covering the base layer with Cellu-Clay
Now for my favorite part of the sculpting process. I mix up a homemade paper mâché clay and thin it enough to spread with an offset spatula (you can find a similar recipe here). I apply it directly onto the dried half-sphere, smoothing it out until the surface looks even and free of dips or bulges.

Step 3: Sculpting up the features of the Jack-o-lantern
Once the clay dries, I sketch out the face to place the features, then begin sculpting. I don’t aim for perfection at this stage—carving, sanding, and joint compound will refine everything later. Getting the shapes into a solid ballpark now saves a lot of effort down the line.
After the features dry, I carve out the eyes and mouth using a keyhole saw or a thin, serrated knife. Take your time here—this material is tough and doesn’t cut easily. I usually rough out the shapes with the saw, then clean up the edges using a rotary tool (Dremel) with a sanding drum.
Only after everything fully dries do I cut out the eye and mouth openings. If you cut too early, the wet clay softens the structure underneath, and the face can sag as it dries—like a real jack-o’-lantern left out in the sun.

Step 4: Base painting & installing eye and mouth inserts
Then comes painting. I use high-quality acrylics to mix the perfect shade of orange. For the eyes and teeth, I layer cardstock, paint it, glue it in from behind, and blend it into the interior with more celluclay. This creates a seamless look on the inside of the bowl. After this inner mache dries, the interior of the bowl is painted black.

Step 5: Highlights, shadows, washes and clear coat
To finish, I paint in shadows and highlights, then apply a grimy dark wash (heavily watered-down black and brown acrylics) to give the piece that worn, vintage look. I seal everything with several coats of semi-gloss spray, inside and out.

And just like that, it’s ready to grace a table for Halloween.
This piece has already sold, but I’ll definitely be making more for the 2026 season.
