Head Failure #2.

 Here was our second head attempt. We did it in paper maché, which felt miraculously light. I thought for sure we'd have no problems with it at all; it was just that light. For this all we did was put plastic wrap over the clay sculpt and then do regular paper maché techniques over it. 

 For extra support, we cut out pieces of pool noodles and hot glued them inside where there were crevices.

 The paper mache head was a fair bit smaller as well, as it was nowhere near as thick as the resin'd fleece. So I had to make a new tongue, the bottom one. It also had to be flatter due to how much room was inside the mouth.

 Then, since at the time we didn't have much else option, we used the plastic mesh thing I created. I learned from that, that the fan was then way too far from my head to feel it (so any fans need to be close to the top of your head in a head like this). 

 The two were fiberglassed together for ultimate strength.

 We also covered the head in a LOT of mod podge. It made it very hard, solid and durable. I felt really good about the actual head on this one--not so much the attachment system, but the head itself felt really good.

 Then I painted the entire head several times in Plasti-Dip. I used a whole can--that stuff worked really well, made it sturdy and strong. I definitely liked the result I got from it.

 But then the head contraption started to fall apart so I took some pinboard, screwed it to the piece, duct taped it in, and hoped that would work. It seemed to work fine, and still has stuck together.

 Despite how much scaling I've done (two heads now), it didn't really get any quicker. Takes about 13 hours of nonstop work for me to do the entire head, which isn't too bad.

This head weighs 6.5 lbs, which is a fair bit lighter than the previous one. Unfortunately, it's not enough, as I can't wear it for longer than two minutes. The average human head weighs about the same as this one, so we're currently trying to figure out how to make one lighter than this.

Currently the options we're looking at:

- Making one from solid pink insulation foam. I really don't like the idea of this as it's very hard to get the mouth to shut all the way with that, but many have gotten this to work.

- Making one from solid green upholstery foam. Haven't found anything this big being done with it, and I feel like it may be too heavy, but math may be in my future for this one.

- Some sort of heat form plastic. 

I sure wish I had a 3D printer, ahaha. There are some people that have great deals for projects and will print things you need for you, but they usually charge by the centimeter and something this large would be insanely priced.