(NOTE: This is only a full face mask, not an over-the-head mask. Hat, dress, and shoes not included in tutorial... Neither is the knife.)
Step 1: Gathering Items
A foam head (I got mine at a wig store)
Plaster bandages (at a craft store such as Alard's or possibly Michael's)
Activa Fast Mache (Or any other brand of papier mache)
Inks (red, orange, and yellow), food dye works just as well
Paintbrushes (not the makeup brushes shown)
Newspaper or plastic tablecloth (so you keep a clean workstation)
Step 2: Prepping the Head
(EDIT: Not shown in the image, I added some cloth over the front of the head and face to round it out and then wrapped that up in extra cling wrap to add more volume to the head so it will have more of the 'bubblehead' look)
Step 3: Plaster and Water
I set out a bowl of warm water (not hot, not cool) and began cutting the plaster bandages into 6-7 inch strips. Don't be afraid to cut a lot of strips, you will be using a lot to cover the head. Start with an 'X' across the front of the face and then begin laying down a starting layer of the bandages. Let it dry and continue to repeat the process until the entire front of the face is wrapped. (NOTE again: I made the mistake of wrapping the entire head without properly measuring my head. I was unable to cut it properly so it would go over my head so I was forced to cut off the back part and discard it.)
Step 4: Drying Time
Step 5: Mache, Dry Again, Then Sculpt
Again, let this dry for at LEAST a day, making sure it is fully in the sun. so it dries evenly.
(NOTE: Looking back, I probably would have done this part in layers; laying a thin layer of the mache over the mask, letting it dry, then another layer, letting that dry, and so on until you achieve the thickness you desire)
Step 6: The Eye Has It
Step 7: Painting
I made a mixture of cream-colored acrylic paint and some grey to go over the entire mask. But you may use whatever colors you would like. I let that dry and then gave the whole mask a dusting of Ben Nye's Neutral Set powder so there were no shiny parts of the paint. You may use any kind of powder, though I'm not sure how baby powder would work.
I used black acrylic paint to fill in the eye and other indentations on the mask and let it dry before going over the eye with some purple, black, red, and even blue eyeshadow for added richness. For the rusty areas, I just made on a mixture of red, orange, and yellow drawing ink and dabbed it on with a paper towel. I also used some blue paint for the veins and blended them out a little with some blue eyeshadow. I went back in with the same ink mixture and just let it drip down parts of the mask that I thought would look good. (NOTE: Make sure you either do this outside or have a paper towel or other piece of scraps underneath the mask so that the ink does not stain your work area. Also wear gloves; I did not and ended up with ink all over my fingers.)
To cover up the exposed eye, I simply hot glued a bit of cut up fish-netting onto the back of the area. Since this mask was hand made, I also drilled two holes on the sides and double-knotted a bit of a thin elastic band so it would hold easily and securely when worn.