Step 1: Materials
plaster strips from a craft store
balloon & inflatable packing material
acrylic paint in various colors
drill & small drill bit
newspaper for stuffing
for the sound:
digital recording module
non-mercury tilt switch
soldering iron & solder
Step 2: Making the plaster mask
Coat the face in Vaseline or (seen here) plastic wrap, being sure to leave openings for breath either in the mouth or nose.
Dip each piece of plaster in warm water and lay over the face, overlapping slightly until the face is covered.
Let the mask dry completely before removing. It should take 20-30 minutes.
Step 3: Completing the head
I used a piece of inflatable packing material to create the neck form, but a smaller balloon could also be used. Cover the neck as you did the skull, again being careful to overlap each piece slightly.
Step 4: Painting your zombie
On top of the white was a diluted mixture of orange, grey and more white to give a slightly decaying flesh look.
Purple and grey made for bruises, and red was needed for blood, of course.
Glow-in-the-dark puff paint was used for lips and eyeballs, and final details were added with a sharpie. The lips were colored over again with a pale lavender color, but they'll glow through the paint, as it was very dilute.