I ended up using ordinary flexible wall filler. The kind you use for repairing cracks in plasterboard. Lol. Just used it more like a clay for the ridges and stuff and then sanded the whole thing down. Should have taken more time on the sanding as there are still visable pits and striations that the painting brought out. :-( I agree with you about the eyes, they definately needed more work.
All in all though not bad if I do say so myelf. Won't win me any awards at a cosplay event (apart from maybe the cost of it!) But for a night on the tiles in the local clubs on halloween? I reckon I'd get some amazed faces!!! Lol
Definately gonna try bondo (resin?) On the next one though as the 'flexible' wall filler has started cracking around the top of the nose. Luckily I sealed it with pva before painting so its not going anywhere, looks a bit unsightly though. Live and learn! Lol.
Thanks for all the feedback. I appreciate it. And when my next one is started I'll post the full evolution of the process for everyone.