STEP 1- NEXT
First things first! You need to build a base to create your head off of and attach the foam to. This step can be completely skipped if you buy a balaclava. I prefer to make my own bases because it’s cheaper, more form fitting, and you don’t get the missing gap of fabric in the front of the face.

To start off, you’re going to need a realistically shaped and sized mannequin head, preferably one with a 22in forehead (which is the average). You will also need some nice, stretchy performance fabric or Lycra, black is the best color to use.

Take the mannequin and lay it to some paper and trace the shape of the head, creating a pattern you will need. It helps to add about an inch around the tracing to allow for seem allowance and a more comfortable fit. Then cut out the pattern.

Next lay the pattern to your stretchy fabric and trace it using chalk or a marker, then pin the two sides of the fabric together in preparation to feed it through a sewing machine. Because the fabric is stretchy you have to use a sewing machine to sew the pieces together.

Once sewn together, cut off the excess fabric and put your now created base on the mannequin with the seem facing out so the inside is nice, smooth and comfy. Once on the mannequin cut out holes for the eyes and a mouth slit. You can also use your own head instead of the mannequin if you prefer, just be careful and don’t cut up your face! You are now ready to foam!