You don’t need expensive animatronics to make a statement this Halloween.

This DIY PVC clown structure is lightweight, wind-resistant, and fully customizable.

You can swap out the clown face for a skeleton or ghost mask, adjust the pose, or add LED lights to the eyes for an eerie after-dark glow.

The long, draping cloth and exaggerated limbs give it that haunting, skeletal silhouette that looks alive when it moves with the breeze.

Materials Needed

• 1-inch PVC pipes (5 pieces, 6 ft each)
• PVC elbows and T-connectors
• Foam mannequin or mask head (clown face preferred)
• Black cheesecloth or tattered fabric for draping
• Spray paint (black and gray)
• Zip ties and duct tape
• Old gloves or mannequin hands
• Red wig or yarn for hair
• Plastic pumpkin or prop accessory

Step-by-step Guide

Step 1: Build the base frame using PVC pipes and T-connectors.

The legs should stand about 6 feet tall, with the torso and head adding another 3-4 feet. You use cross supports for stability.

Step 2: Attach the arms using angled PVC elbows so they reach outward.

For a creepier look, make the arms slightly longer than human proportions, around 4 feet each.

Step 3: Secure the mask or mannequin head to the top of the frame. Then wrap duct tape or foam padding around the neck area to keep it stable.

Step 4: Drape tattered fabric or cheesecloth over the frame, layering until you get that ghostly texture. Let some pieces hang loose for wind movement.

Step 5: Spray-paint the frame black and gray for depth. Once dry, add details like gloves on the hands or a small pumpkin prop dangling from one arm.

Step 6: Finish by attaching the wig and adjusting the pose, slightly leaning forward gives a more menacing presence.

Tips:

To anchor it outdoors, drive two metal stakes beside the legs and zip-tie them to the PVC frame.

At night, shine a red or purple spotlight from below, it’ll make your clown look like it’s watching every step you take.