This year we made Santa Jack Skellington. The mask was made from a 12" acrylic lamp globe from home depot and the mouth was cut out and screen was added to fill it in. We screwed in a hard hat so that the mask would be comfortable to wear around trick or treating. The eyes, nose and stitching were painted on.
As for the fabric, we selected red and black pin striped fabric purchased from Joannes craft store and lined the Santa hat, arms and pant legs with white trim. We also selected a yard of crafting fir to use for the beard.
To finish it off, we used a pair of skeleton gloves on the hands.