Hey Jerryb7,
Been meaning to get to you. Sorry if I'm a little late on the response. Happy to help. My process for the cowl. First I made a casting of my head using some plaster wraps I purchased at Jerry's Artarama. Its kind of a crude but cheap process. I tried to do this on my own at first (dont do this). Especially if its your first go. Get someone to help you with the casting. Once the cast was done, I bought 10 lbs of water based clay. Preferably 2 different colors, 5 lbs of each. Get your cast clean and then line the inside with Saran Wrap. Then stuff your cast with the clay. Really push it in the face to get your impression. This is not as perfect as doing a silicone casting but it will get the general shape and features of your face without the hit to your wallet. Once this is done, use the second color of water clay to design your cowl. Try to clay cowl at least 1/8th to a 1/4" thick. After the model was completed, you can make your cast of the cowl. I would suggest getting some silicone for this part and some ultracal. Build up the Silicone and then the ulracal over that. Once it is done you should be able to remove the silicone mold fairly easily. After that I could pour the Vytaflex and make the final product. This is an overview of what I did. If you have any specifics you want to know about, hit me up.
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The suit was all over the place. Some parts were foam, others material. Watched sewing videos. It was crazy. Think my wife was gonna flip if it took any longer than it did. lol. If you have questions about a specific part of the suit, I will be happy to share what I did to make it.
