This is my first time making any sort of mask, so bear with me if I'm suggesting something incorrect. :) The end result turned out pretty spectacular though!
Most of these pictures were taken by friends while we were making the masks (ie. not for the purpose of an instructable), so they're not necessarily the best for an this and I'm probably missing some photographic steps.
If anyone decides to use my project, PLEASE send me some pictures! I would love to see your masks!
Step 1: Gather Ingredients
Plaster Bandages - these are bandages already coated in plaster (meaning you just need to add water). I found mine at my local art store.
Lots of newspaper
A Bucket of warm water
Headband to hold up your hair
Metallic Acrylic paints
Step 2: Prep work
Find a nice spot on the floor and lay down the newspaper. Although this isn't too messy if you're careful, you don't want to get plaster all over the floor.
Get a few globs of vasaline and rub it all over your face. Make sure to cover your eyebrows, hairline, sideburns, and any other facial hair well. It can be pretty painful to remove the mask if you forget this vital step!
We wanted to be able to talk through our masks at the book launch/movie premiere, and since plaster would have set directly over our face we wouldn't be able to move our mouths. If you unroll some aluminum foil, fold it in half, and squish it over your lower jaw, that should leave enough room for you to talk behind the mask. It will make your final mask look somewhat gorilla like, but I think it's even more menacing. :)
Cut two pieces of straw about two inches long. These pieces of plastic will fit glamorously up your nose, enabling you to breathe.
Cut your plaster bandages into strips of varying lengths.
I'm blind without my glasses and I don't have contact lenses. What I did was take the lenses off my old glasses and laid them over my eyes. Once the mask comes off, you can glue the lenses inside the mask.
Step 3: Start making the mask
Step 4: Modify mask
Once the mask is off your face, you can now shape it with the remaining plaster. I added more depth to the forehead, nose, and cheeks. I also added a 'ring' around the eye sockets as seen in some of the official death eater art. Once you're happy with the mask, let it dry overnight resting on a ball of aluminum in case it starts to buckle.
Step 5: Paint the mask
Once you're done painting, let it dry. Attach elastics/ribbon to the back using super-glue (I needed an anchor above and below my ears, as well as over the top of my head. The mask is a little heavy!).
I glued my lenses to the back of the mask using a glue gun. I also left a ring of glue around the lenses where it makes contact with my face, as I found without that extra space my eyeballs were pressing up against the lenses and it was quite painful. Just wear contact lenses if you have them!