Making a custom bio mask

[Alpha Predator]

I need some help on what to make it out of or what to use as a base design??

 

[Hunts With Man]

If you haven't seen it yet, here's an extensive photo set of... well, a ton of different bios.
http://www.thehunterslair.com/index.php?showtopic=21321

I've seen a lot of people turn out very good looking masks out of cardstock, fun foam, even paper mache. I think there's one or two around that were done in steel. That said, generally the best film-accurate bios are cast from resin pretty much the same way the originals were done. That is, sculpted in clay, then a negative cast made with silicone and/or plaster, and the final product done in casting resin.

Poking around in the huntorials section will net you a vast array of mask construction knowledge.