The initial build was foil bulked out over a plastic pre-made mask. I took a pattern off the back of a wig head to create a foam shell, then I painted the whole thing in polyester resin. I then bulked it out with fibreglass, refining the shape, and going back and forth adding and removing material until I was happy, and could start building up car body filler. When I realised that the project wasn't going to be  wearable mask for myself, and would need custom fitting to most other people, I decided to bulk out the mask into a shape I had initially decided against for weight reasons. 

The horns were fabricated out of EVA foam with a pvc pipe skeleton, then layered in more fibreglass and finished with more body filler. 

The paint job took lots of layering of greys and bones for the correct shading, then masking for the pattern, and lots of good brush control for the edge lines.