I really wanted to go as her for Halloween but couldn't find anything online that looked like this. So I decided to make it out of cardboard, tape, some bolts, and a lot of spray paint.
It took me a few weekends but I trashed my first prototype. My boyfriend went as billy the puppet and we won the costume contest!
Step 1: Carboard Cut Out
Then I used the bottom of a drinking glass and a ruler to make the outline. The top and bottom of the mask will have the scalloped edge. The part where the two parts touch in the middle (where your lips would be) is just a rounded edge.
Then you want to create a thicker piece of cardboard to go over your head and hold both sides of the jaw pieces you just made. You can mold it a bit but the weight of the jaw pieces and lock on back should hold it to your head and make it easy to take on and off.
You can see in the picture with Billy how the side pieces look. I glued a longer piece to the jaw pieces and wrapped them around to connect with the head piece. I did the same with a piece in the back. Make sure to put your head in and measure!
Step 2: Newspaper and Spray Paint
Next, go to Home Depot and find some good rusty looking spray paint. They usually have some metallic brown or silver. You can also mix and match. This is up to you. I used a rust colored hammered finish. Paint all your pieces and let them dry outside.
Step 3: Finishing Touches
Once you have the basic mask done, you can start adding extras. I got some nuts and bolts and actually drilled some holes in the front of the mask. This definitely made it look more realistic. I also found a tubing piece at Home Depot so I added that to the top of the mask (see pic). And I used a real padlock on the back. This helped weigh the mask down on the bottom and even out on my head. The timer was a print out of an image I found on the web and the bottom of a plastic cup! I glued a strip of thin cardboard around it and glued it to a board with some spray painted thumbtacks.
The costume was a huge hit and people couldn't believe I made it myself! Let me know if you try this out!