I'm making a mask for a guy with a head circumference of 23.5 inches. I don't think that it would fit.
Well, then this a great "life lesson" moment. You said you would make one for a specific head size. You dropped it. Now you have to either go back and fix it or make another. You are using the cheapest method out there. You just have to put in the time to fix your oops. We have all been there and done that. The real makers have encountered many setbacks and dove back in to make something awesome. Here is your chance to make good on your promise and create the faceshell for your client/friend. So roll up your sleeves and make another!
I'm wanting to make it pretty sturdy but also flexible. your idea isn't bad but I've heard plastidip is easily removable and has a rubbery feel. I want something that will stay together and have a smoother surface.
Okay the other solution I can think of would be to 3D print a shell if you have access to one say at a library or know somebody. Yeah it kind of has a rubbery feel although that feeling is great for keeping masks in place, I can't speak to the easily removable part as I've only used it on one project and it seems to stick just fine, however, it has been a low use project.
I personally wouldn't go the bondo route as it will be too heavy to wear for any length of time and if you make it thin enough to lower the weight it will then be too fragile.
Well is vacuuforming hard or expensive?
