I am just going to present a series of photos that show the progression of making the head base from start to the point that it is ready to be taped. Most of this work was done in about four days of off and on work and I have never done anything like this before. All that is needed material wise is a roll of 1/2" thick foam, a styrofoam model head from the local big box store and a hot melt glue gun.
The only tool used for cutting and shaping was scissors.
That's is Pocari Roo online :-)
Had to test if I could actually see out of it. My wife was laughing her butt off.
Setting my bifocal lenses into place.
Working on the lower jaw.
Attach elastic straps for wearing the lower jaw.
Keep trimming the foam until you get the shape you want. If too much foam is removed then more can always be added.
Just a short video to check for range of motion.
Test of the lower jaw.