I got started with the helmet base, which I give 100% credit to Evil Ted Smith and his foam fabrication videos. If you haven't already, go check them out and learn some neat tricks of the trade! Really helpful video series.
Anyway, I started by grabbing my new Ed head, from Monster Makers. It's the right circumference, though the rest of the head is pretty skinny. We'll work on that, though!
Anyway, I covered the head in aluminum foil.
Also, those cuts you see, the small darts? That's another trick I learned from Evil Ted's videos: alignment marks! Helps to make sure everything fits pack together the way it should. Literally a godsend. :D
So I flattened out the pieces, then transferred them on to paper and enlarged them a bit, to account for the 1/2" thick foam (and the slightly small head). Once that was done, it was on to the foam!
Next came the face plate, which you can see the early sketches for in the above picture. I drew out one side, then traced it, flipped it, traced the other side, and gave the inner seam a slight angle in the middle. The result:
Next, I threw on some more 1/2" foam on the back, as more filler in the huge empty space.
A week passed, finally got the yarn, gathered a bunch of strands and cut the ends apart, then tied one end and secured the knot in the hole on the conning tower. Then I brushed the strands as best I could to separate them.
Here's the final product! Hope you enjoyed that one as much as I did.