I used one of those skull faces off a fogger machine from Wal-Mart because it was big, but any plastic-like skull face will do. First lightly spray it with W-D 40 to prevent stickage. Now tear tissue paper into strips (don't use newspaper! The tissue paper allows details to come through). Dip each piece into a wall paper paste mixture and apply to the skull. Use a paint brush to press the tissue into recessed places. Build it up to at least 5 layers. Let dry then carefully peel it off the skull (you might have to make a split under the chin which is easily repairable). Next insert a balloon, rounding out the back of the skull. apply several layers of tissue paper to the back of the skull, let dry, coat well with polyurathane. Then antique with black spray paint by spraying and wiping before it has time to dry.
Using a razor knife, cross cut the bottom several times. Important! Because these are 'just so cool' everyone wants to touch and squeeze, so I highly advise that you spray in some insulating foam at this stage. Insert a 3 liter coke bottle, before the foam hardens, secure into place with masking tape.
Stick an old broom handle into the coke bottle, secure with screws. Wrap a piece of pool noodle onto stick (a pool noodle gives a softer padded look, but a board would work). Run a screw thru the noodle into the stick to keep it from sliding down.
Using a piece of wire, "sew" in and out along the edge of a piece of fabric, gathering it tightly. An old sheet works good but if you use fabric, you'll need at least 2 to 3 yards to get enough fullness. Wrap around stick. Now wrap another short piece of fabric around the neck. Lightly spray some black paint on fabric to give it an aged look.
Several of these in a row with one person dressed in a matching costume using one of the skulls (split in the back) as a full head mask is a good effect.
If I got you confused, or you have any comments or questions,
don't hesitate to concatact me at beasleys@brightok.net.