: I was thinking of making the 1/2" minicel inner liner, saran-wrapping it
: to my head and under my chin, and then making a plaster mold from
: that---likely use this as a male mold to make a female mold from.

Consider making a plaster of paris mold of your unpadded head, (takes about 1/2 an hour) and filling that casting to make a lifesize copy of your cranium. Then use that as a base for any building projects. It is much more maneuverable than trying to take casts off of your own head.

Once you have the lifesize copy suitably padded you can cover it directly with glass and epoxy ( male mold techmiques) or amke a new female mold -- which would probably be easiest to do in a bucket, with the plaster copy inverted and immersed in the plaster of paris. You'll find it easier to attach padding to the plaster copy of yourself (whether with hot melt adhesive, or double stick tape) than to figure out how you are going to wear the padding, while standing on your head in a bucket of wet plaster so you can make your new mold.

Should you decide to do your whole head, be sure to stock up on the fat drinking straws you get when you order milk shakes. A couple of these between your lips will let you breathe for the 5 to 10 minutes it takes for the plaster to set up, and form a "life mask" of your face. A plastic bag over the hair keeps that out of the mold, too.

Fill your mold with papermache, seal it with an off white paint, and decorate with regular cosmetics to get a perfect flesh tone -- and you'll have a neat extra head to use in any number of diferent ways next halloween. A cheap wig attached to the top adds to the gruesome look.

PGJ