Thank you :) How was it you got the initial shape of the head and made it come out 3D? Sorry if my wording is weird like I said not cosplayed much xD
Not at all, I know what you mean! Ā Here are some links to posts I made during the process of creating the head:
http://squigglydigglydoo.tumblr.com/post/158215618882
http://squigglydigglydoo.tumblr.com/post/158255568112
In these posts, you can see the interior structure of the mask, before I cut out the mouth through which I see. Ā I started with a cheap bike helmet, stripped of its plastic coating and reduced to just styrofoam. Ā On top of that, I placed a chunk of upholstery foam (henceforth just referred to as āfoamā) to heighten the mask, and then I made a foam ring to fit around my neck that I could still slide over my head.
After that, as you can see in the first post, I made four strips of foam, each extending from the ring to the top of the foam chunk on the helmet.  One strip in front, one in back, one on each side⦠but before attaching the ones on the sides, I created two quarter-circle-shaped hooks of foam that I attached to one another at the top of the foam chunk on the helmet.  These gave the outline of the horns from the front.  The strips on the sides were then attached to these hooks at the very tops.
The lengths of these strips were adjusted throughout the process to achieve the silhouettes I wanted both from the front and from the side.
After the very basic framework was created, I began to fill in the areas between them with more foam, starting from the horns. Ā This was just a lot of eyeballing it, and as I added foam so as well did I shave bits of it away so that I got a nice smooth shape for each horn, tapering to the tip and widening out towards the base. Ā When it looked right, I continued the process around the rest of the mask, as you can see in the second link.
You might also notice that I did not fill in EVERY hole in the mask, especially in the back, as while wearing this costume Iām likely to become very hot. Ā Having holes in the foam allows more heat to escape, even if those holes are still covered in fabric. Ā So I did the minimum needed to maintain the shape, while leaving slits and holes in the foam for venting.
http://squigglydigglydoo.tumblr.com/post/158299479207
Finally, it was time to cover the thing in fabric. Ā I chose black and white minky, as itās very soft and plush but not quite furry ā Bendy isnāt a cat or anything, after all. Ā Before cutting the fabric out, I covered half of the entire foam head (split down the middle for symmetry) in tin foil and then again in duct tape, keeping it as tight to the shape as possible. Ā This was going to be the pattern ā I drew where Iād need to cut the pattern so that itād lay flat directly onto the tape, then cut it off and transferred the shape to the fabric, expanding the shape by ½ inch all the way around (allowing for seams). Ā I wound up with two pieces of black: one for the back, one for the front. Ā One piece was needed in white for the front.
Before putting these onto the mask, I cut out the mouth shape, estimating where it would need to go so that I would be able to see out of it. Ā Once it was in a place and shape I liked, I then attached the fabric: starting with the back, then the white face, then the black front. Ā I used spray glue to put them on, then VERY CAREFULLY made my seams with hot glue, turning the edges of the fabric inwards where they overlapped. Ā The remaining fabric near the hole at the bottom of the head was tucked in and secured with more hot glue. Ā (Seriously, be VERY CAREFUL with this. Ā You might need somebody to help you hold things in place as you glue them. Ā DONāT BURN THEIR POOR FINGERS.)
Once all the minky was attached, I created the teeth shape out of white chicken wire (taken from a mesh dome used to cover food to protect it from bugs; I got mine from a Dollarama) and put hot glue all around the edges so that they wouldnāt be so sharp and dangerous. Ā I then covered the teeth in the fabric from a pair of opaque white tights, stretched thin so that I could see through them when they were close to my face. Ā (Note: I can still only barely see through them, and I need a LOT of light to do so. Ā Iām sacrificing quite a bit of visibility for this costume, so bear that in mind.)
I very carefully hot glued the teeth into the face, where Iād cut the hole in the same shape into the foam earlier. Ā After they were solidly in place (it took a few tries), I VERY CAREFULLY Ā (so as not to get paint on the minky) painted the black lines onto the teeth.
After that came the eyes. Ā Since Iām not seeing through them, they could just be attachments. Ā I created the shape out of the plastic from the side of a thoroughly washed milk jug, then covered those pieces on one side (tucking the edges around the back side) with the black minky fabric, using the WRONG side of the fabric to be the outside this time. Ā I didnāt want fuzzy eyes ā I wanted smooth eyes. Ā Once the eyes were covered in fabric, I gently dragged a razor over them to remove bits of fuzz, then I sprayed them with clear paint sealant to make sure they stayed smooth. Ā After this, I attached them to the face.