Head material questions

Hey guys! My friend is having me build her a Typhlosion mask, and I have a few questions about the construction.

1. Base: Would a baseball cap be strong enough to hold this type of mask on someone's head? I'm afraid of it tipping forward. We would like more structure than a balaclava, but a bike or construction helmet is probably too bulky.

2. Foam: I live very remotely, and we're doing our best to source things in my town to save on shipping. The only foam I will be able to buy are those yellow camping pad things. Is that an appropriate material or should we order the green stuff instead? I actually got access to Joannes right after posting, so now I have obnoxious amounts of green foam :)

3. Fleece: This mask will be "skinned" with fleece. I know any lumps and bumps in the foam will show through; will a layer of batting be enough to prevent this or should we purchase a Surfoam Shaver?

4. Vision Material: The wearer will see through the mask's tongue, and obviously I would like the tongue to be pink. I was thinking of stretching pick nylons over this stuff. Conversely, I could just paint the mesh, but it would really show the texture. Any suggestions for this?

5. Glue: I have read that hot glue tends to fail when it gets wet. Should I be using E6000 plus Scotch Super 77 for this project instead?








Thanks so much guys!