Cardboard frame (yes, I did put my head upside down on the floor to trace it):
And then covered it with expanding foam!
I did this a couple days ago and I just foam the bottom half my head just now. Tomorrow when it's dry I'll carve it =P
Then, the plan is to use that to make my pattern both for the skull cap thing itself, and the large protrusion things that are part of the helmet. The balloon/bag method wasn't working out too well for me =(
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