This year I decided to make my own mask from scratch. I created this character inspired by a classic mask called the Ghoul. I call this piece "Where's my Grave?"
Step 1: The Sculpture
I started by sculpting the mask in clay on a bust. I used plastic spheres for the eyes and acrylic teeth.
Step 2: The Latex Casting
I molded the sculpture in Ultracal 30 and cast it in mask latex. The first casting came out nearly perfect with a very small seam.
Step 3: Painting the Mask
I spent many hours airbrushing the mask with many layers of color. I then sealed it with an acrylic varnish and glossed the eyes and mouth.
Step 4: The Finished Costume!
I got an old suit and cut up the arms and legs to look shredded. To make it dusty I ground up cat litter in a coffee grinder and poured it in a trash bag. I put the suit in the bag and shook it up. I sealed the dust on with a clear acrylic spray. The rest was all performance having fun as a goofy zombie!