Since I had to make a head mould for my new mask I thought I would share how I did it in case anyone needs to do it themselves. These were pretty much the instructions from Custom Made Masks.
You need:
• Nylon hair Cap available at art supply stores (I simply used Saran wrap around my head)
• Vaseline/Moisturizer to cover head and face
• Saran Wrap to cover eyes, eyebrows or beard
• Basin with warm water
• Rubber gloves (optional, I did not use these)
• 2 rolls of 6” wide plaster bandage – Available in art supply stores, I used the 3" rolls
• Scissors
• Newspapers - lay out on area you are going to use because you are going to make a mess.
1) Fit either cap or Saran wrap snuggly over the head covering all hair. Smooth out all wrinkles on cap where mask will be.
2) Apply an even coat of Vaseline over entire cap and face. Do not leave blobs of Vaseline. Apply extra Vaseline over facial hair, especially eyebrows, eyelashes, sideburns, beard or mustache.
3) Apply Saran Wrap to cover eyes, eyebrows and eyelashes. Smooth over contours of eyes and into corners of eyes. Avoid wrinkling Saran Wrap.
4) Open 6” wide plaster bandage and roll out onto table. Cut roll into half making two 3” wide pieces. Cut into strips 8” long.
5) Dip plaster strip into water until fully saturated, then remove excess water.
6) Apply each plaster strip after dipping strip into water. First form the border of the mask starting with the top back of the head and working downward. Don’t apply plaster around the curve of the back of head otherwise you won’t be able to remove the mold from your face. Cover entire ear working downward to cover angle of jaw. Cover underneath chin and jaw just above Adam’s apple then work upwards on opposite side of head overlapping each plaster strip. Avoid all wrinkles in plaster whenever possible. Once border is complete apply plaster to head working across head and from top to bottom. Smooth plaster over cap as you go. Gently push plaster bandage over corners of eyes and smooth over. Cover over the bridge of the nose, leaving the nostrils open to breath. Apply plaster strips over the mouth. The entire head and face should be covered now. Repeat plastering process until roll of plaster bandage is used, applying two to three layers.
Let mold setup approximately 15 minutes.9) To remove mold, hold cap at back of head, then gently pull mold forward to top back of head. You’ll feel a tugging sensation until the seal is broken then the mold should slip off easily.
Here are some pics of what it looks like once you have it all on. I couldn't get in between start to finish since your assistant's hands get really dirty.
This pic is of the inside of the mold, weird looking, reminds me of when Han Solo was frozen. hahaha
It is a relatively easy process that in total takes about 30 minutes. It seemed intimidating when reading the instructions, but not too tough as long as you have someone to help you out. Let me know if you have any questions.
Hans
