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Full head mask,
in progress,
hopefully with articulated jaw when completed, if time allows.
Re-useable skull form is newspaper and tape (masking tape and clear packing tape for rigidifying and smoothing). That form was built directly over a loose copy of my head, made with Duct Tape filled with newspaper.
Mask itself is (for now) paper mache strips (coffee filters and outdoors carpenter's glue, diluted just a bit with water). Note the wrinkles, caused by crumpling in one direction and applying directionnally. Those wrinkles provide strenght as well as looking good, if well applied. the effect can be softened by adding a layer or two of thin soft paper in the usual flat method.
When finished, the mask openings and jaw pivot points will be lined with wire and more paper, for strenght. Padding inside will be done with a soft foam, lined with a non-porous foam (Fun Foam, also called Foamie) to prevent sweat absorption by the mask, and provide comfort.
The eyes, nose and jaw openings will have fine see-through black mesh to hide the wearer.
The dream is to also build a pair of giant skeleton hands, but I'm not really counting on it for this Halloween, too many projects at once.