Instructables
This was inspired by a recent article in Makezine's blog. Since that article was primarily photos, so I thought I'd note down the actual technique and some changes I made.

More information on this project is available at http://www.creatrope.com

Some of my Halloween work is also in other instructables:
PVC Mannequin
General Grievous with Mechanical Arms
 
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Step 1: Forming The Skull

A godzilla/tyrannosaurus skull is formed from box cardboard. Two upper jaws, two lower jaws, and a 2" strip across the back and top, and a strip down the center top skull to the nose, and one running across the upper jaw and the snout. This is too coarse a lattice to lay paper-mache on (it will be too blocky), so a lattice of 1" masking tape forms a tighter grid.

The components are glued together with hot-glue (best) or white glue (and then staple the pieces so you can work immediately). I found staples were not enough to keep the skull stable.

Step 2: Covering & Painting

Covering

I used the paper mache recipe to cover
the outside with newsprint strips, let dry, repeat on the inside to cover the fragile lattice. It's best to cover anything you want to paint eventually.

At this point I did some dino plastic surgery, cutting down and shaping the jaw.

I added brow ridges to the original design by twisting some paper, taping place over the eye areas, then paper-mache'ing over those.

I let everything dry, then covered with a thin coat of mod podge to give it some further protection.

Painting

You'll need a thickish paint to cover the newsprint. I used an acrylic that I had laying around, combining several shades of green, barely, to put some textured streaks on the skull.
adyingcow6 years ago
Hey, thanks for this grade a costume! I had a blast for halloween, and people LOVED the costume. If you wanna check out a picture, just look at my profile picture.
creatrope (author)  adyingcow6 years ago
Wonderful picture! Thanks for the comment, and taking the time to post your photo. Nicely done, I can see the 'family resemblance'.
tried this a while ago but the cardboard skull got saturated and collapsed
you didnt squeeze enough of the paper mache off the paper. The first layer of my mask was saturated too because of that reason. Make sure you take off as much of the mache on each paper before you put it on
This made my day. So cool!
hay_jumper8 years ago
This is the awesomest.
I was trying to think of how to make a Yoshi costume to go along with my gf being Mario, and I think this is it! Thank you for posting this!
i think ill just make the mask it looks fun
enero8 years ago
Very cute! If I had the time I would make one for myself!