This was fun. The face is hot glue from a silicon-latex mould.
The cranium is papier mache over a carved polystyrene block.
Here are the design sketches...
To get started, a face mask was lined up....
to compare with the pencil designs...
. the design was drawn onto the block...
Then some roughing out with the carving-knife ...
As the shape developed, masking tape was used to hold the mask to the polystyrene block
The block was carved away until...
The actual mask is a hot glue variation from the same mould that the latex mask was made from. This was lined up with the papier mache cranium.
and glued on by melding the hot glue to the papier mache
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