So I've been thinking of trying to make a Batman cowl out of foam and I'm wondering if there are any templates out there. I have a rubies cowl but I think I'm either allergic to latex or nauseated by the smell either way I can't stand wearing it. I would like to have a complete costume for the dark knight rises premiere so any help would be appreciated. If worse comes to worse I'm going to try and modify the Captain America helmet.
Any ideas which foam I should use for the mask? I have anti fatigue mats and craft foam, I'm debating which would be best. Any thoughts?