Sew and Sew

The first thing I did was went out and got one of those foam head forms. They are decently cheap and boy will they save you in the long run. but really it does help to have something you can shove the head on while working on it. Now I dont have pics of just the mask however i do have some of the very early stages.

Hopefully you can see what I mean by the cover. Also you can see the beginnings of the lower jaw. It is carved out of 3 inch thick foam. I believe the stuff I use is called airtex foam but i could be wrong, you can find it at most fabric stores and its sold by the yard however it is pricey i warn you so keep an eye for sales. Honestly this part can take some patience and it helps to draw out the general shapes before hand but yeah cut into as best you can. I used a serrated kitchen knife [for the large cuts] and a pair of scissors [for the smaller things]. I cant really give much help her besides make really small cuts. 

after that it was merely a matter of carving it out and hot glueing it to the face mask. Not the eyes in this picture are not the final eyes. They were a place holder while I was testing out shapes. Now it the jaw does not line up exactly with the top of my head, A decent portion of my head top is not covered in foam so I can attach the wig [which will hide the head portion]

As you can see it looks a lot more natural here. After This I added in the eye ridges and then covered it in fleece. Basically stretching it till it was taunt over the foam and there were as little seems to sew as possible. After that you add in the actual eyes [For this I just used white craft foam with sharpie much to the annoyance of my friend, but hey i was pressed for time.] and added in craft foam teeth. I considered clay but to be honest craft foam was the better option all around. Lighter, more durable, and much easier to replace. after that I just glued in the tongue i had sewn up and viola