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!