 There were several versions of Green Hornet and Kato masks used during the entire show, from the early screen tests until the final episodes. The first TV version appears in episode #3, "Programmed for Death" which was actually the first episode filmed. After this episode was shot, molds were taken of Williams' and Lee's faces and form-fitting masks were cast for the subsequent episodes again with several variations to each. This will be up to the buyer/maker/wearer on which version you prefer!  Early screen tests of different actors playing Britt Reid using cloth masks!   Early style masks used in the Green Hornet Promo trailer clip and also in the Batmobile-vs-Black Beauty promo picture!  Early pre-production publicity mask (style #1), 1st screen version masks used in episode #3 only (style#2), Kato's early version mask and hat!  Kato pre-production mask as seen on the Gold Key Comic cover.
Green Hornet Mask Logo Click for larger size 
There was one Van Williams endorsed mask after the show for the 30th anniversary in a limited edition. Click photo to view the "Certificate of Authenticity" 
You can search eBay for "Kill Bill mask" as a Kato-esque mask was used in this 2003 movie.
 As an experiment I made a GH/Kato mask out of one of those cheap plastic Halloween masks, spraying the GH mask with "Hunt Club Green", American Accents, by Rust-oleum™. Again choose your personal preference style!
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