I have a mini metal lathe so that is how I do mine. As far as the teeth I used a block of aluiminum carved with a dremel bit. It sounds like alot of work but it cut it like butter.
Hey darthjones
Do You have some Acurate ANH face part measurement that aren't the bantha rider specs? I see a lot of face parts out there that just don't look right...Would be nice to see some metal parts offered that are accurate(not giant eye stalks with large inner holes or small with small inner holes)and that have the right taper. Looks to me that the eye stalks on all the refence pics have a very pronounced taper or conical shape in the side view shots. I see more strait(tube like with not much taper) eye stalks being offered mostly.
I'm making from scratch not buying a pre formed kit it's not how I roll , I make all my props masks and costumes from scratch.
I enjoy the cahallenge .