VIDEO!
Materials: fiberglass resin ($10), fiberglass resin hardener (optional) ($5), Tube of silicone ($5), caulk gun for silicone ($5), potters clay ($20), ceramic mardi gras mask/ head/base anything to mount the initial clay sculpture on ($5), sandpaper ($3), bucket ($1), silicone barbeque brush ($3)
note: ONLY USE 100% SILICONE!!!!!! ALSO THE FIBERGLASS RESIN WILL EAT THROUGH PLASTIC OR FOAM CUPS. SO USE SOMETHING DISPOSABLE OR USE SILICONE.
1) sculpt the head out of clay on a stand of some sort (I used a ceramic mardi gras mask on a base covered with tinfoil)
2) put silicone tube in caulk gun. poke open the silicone tube. cover the clay with silicone. clay can be dry or damp. if dry, it will crack, so cover the cracks with clay.
3) let that sucker sit for 2 days. dont touch it. if it's thin in areas. cover with more silicone. you want at /least/ 1/4in thick.
4) after you are 100% sure the silicone has solidified, soak overnight or for a day, until you can get all the clay out of it.
5) wash that silicone mold out as best you can.
6) brush in about 5 layers of resin as thick as you can. letting it dry between layers.
7) soak overnight in water.
8) peel out the resin head. DONT WORRY IF THE SILICONE TEARS! YOU CAN FIX THIS!
9) dremel out the hard bits and sand the resin head down.
10) line the INSIDE. not the outside. with silicone for more resilience. or line it with foam latex or some sort of material that will give it some give. I do not recommend lining it with foam.
11) YOU HAVE A RESIN BLANK!