Foam Ghost Rider Mask

I started by templating out the shapes of the skull. (NOT PICTURED) I took masking tape and covered half of a mannequin head, then I drew onto the tape where my skull will sit on the head and I cut that out with a razor blade, right on the mannequin head.  Once I had my overall shape, I marked where my jaw line and where the seams would be.  Then I cut on the lines I marked, with a razor blade and peeled them off of the mannequin head. Once each piece is off the mannequin head, stick it flat to the poster board, and KABOOM, you have your templates (pictured).  Once I had my templates I traced them onto the EVA foam, and cut the pieces out using my trusty band saw.  

To get the right form, I used a heat gun and shaped the foam to look just right.  I glued the individual pieces together with Barge, this stuff is a heavy duty contact cement that will keep the foam together.  The foam will rip before the bond breaks, if applied correctly. 

After that, you'll see that I added foam to build the bridge of the nose, then carved down using my Dremel.  I also carved in the teeth using my Dremel, using a sanding drum and various shaped grinding stones.  

The masking tape will be replaced with elastic, so the jaw will be able to move with the wearer.  

The shiny substance you see on the mask is Kwik Seal. This was used to seal the foam.  It was then coated with Plasti-Dip,

A base coat was applied with spray paint to start the painting stage.