Just a few quick making of images:
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I did some layout sketches when i was in Japan last November.
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Stared off with some nice thick chunks of Styrofoam. Rasped and sanded into the correct shape, taking very fine care to make sure it was symmetrical. then started covering in filler.
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Once i had covered the whole thing and added the wood grain effect i started sketching out the raised detail areas and engraving others.
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I dremeled out the layer of filler where the raised details needed to be.
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I used 5mm armature wire and bent it to shape to match the contours of the mask. This took a lot of finessing.
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Once the armature wire was secured in place i filled around the edges and stippled filler over the wire it's self for the aged metal look.