Well, after calming down and taking my time with the second pull, everything seems to have worked out. It is a learning process after all. Still have some slight dimpling from the registration keys, but I think I can fix that for the next few pulls. This pull involves about 30 oz of Smooth-Cast 65D (formerly Roto-Cast) Overall, we're about 1/4" thick all the way around. It's rough trimmed and the eyes are not even trimmed straight, but at least it fits the model's head. That', I'm very happy about. He seems to be pleased also. So, I'll pull a few more to work out the kinks and start the finishing process (sanding, bondo, sanding, painting, padding and lenses).
Jesse