I made this Jack in the Box costume for my husband for a Halloween costume contest at work. It took about 3 days to make the head. I used a punching balloon and paper mached it, leaving an opening at the base. You can set the balloon in a large bowl while doing this. It had to dry for 2 days, make sure it’s completely dry before popping the balloon. I painted it white added a foam piece for the nose and punched eye holes right below the nose. I also added three foam pieces glued together for the hat and secured these with wire. Then simply painted the eyes and mouth on and had him wear a suit.
The sign was a little last minute, a printed one probably would have been better with whatever Jack in the Box commercial is popular at the moment. Everyone loved it and wanted a picture with him!