Ayyanaar figures, which include the horses in the army, range in height from less than a metre to over 6 metres. They are some of the largest terracotta figures to be sculpted and are painstakingly made by mixing the moist clay with straw and sand for a proper consistency. For the horse, four clay cylinders are rolled out with a piece of wood, for the legs, after which the body is built up gradually. The accessories, such as bells, mirrors, grotesque faces (kirthimukha) and crocodiles (makaras), are made separately as is the head. The parts are joined together on the auspicious tenth day, when the figure of Ayyanaar seated on the horse is given its features. This is then baked in a rustic kiln of straw and verati or dried cow-dung which is then covered with mud. Parts of the larger figures have to be fired separately, joined together and fired again. The faces are sometimes painted red to denote anger and the neck blue to denote calm. The rest of the body and decorations are also painted in bright colours.
The oldest Ayyanaars and horses are found in Salem district. Salem and Pudukottai districts make the most large terracotta horses; the smaller figures, human, divine and animal, are made all over the state. Given the time taken by the firing process, moulds are becoming popular to hasten the process. Ayyanaar figures are found in the village sanctuaries of Chettampatti and Nallur (Tiruchirapalli district), Tirripuyanam (Madurai district), and Vadugapalayam (Coimbatore district).
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