First I made a template to find out the size of my face using a piece of paper, i just held it up and drew the shape of a beard around my face.
Using the template as a guide I made a mold from foamcore. I glued the pieces together with hot glue and covered the mold with papier-mâché to add rigidity. I made sure the mold had a lip around the perimeter.
Step 2: Preparing the Mold
Next I filled the mold with white modelling clay about a half inch thick all around.
Step 3: Making the Stamps
I made three bee shaped stamps which I would use to imprint the clay in the mold. These were made from sculpey polymer clay and baked for 15 minutes at 130 °F to harden them.
Step 4: Imprinting the Mold
I used the stamps to imprint the bee shapes into the clay filled mold. I used 3 stamps so that there would be less distortion in the clay around the imprints I had already made. I slowly made my way around the mold varying the depth of the imprints.
Step 5: Casting the Latex
I used liquid latex from the art store to cast the beard. I carefully brushed the latex into the mold in thin layers using a hobby brush I got at the dollar store. I decided to do 20 layers so that the beard would be quite strong and tear resistant. Each layer took a few hours to dry. It is important to have as few air bubbles in the latex as possible you can use a hair dryer or blow through a straw to pop any persistent bubbles.