I took on this costume for a friend of mine so she could surprise her little boy during his costume party. It took a lot of time to carve the head out of foam layer by layer. Then used spray adhesive to fit all the foam pieces together, then sprayed the outer part of the head and stretched fleece over it. The blue band is hand stitched on to the upper fleece and lower fleece parts. I lined the inside of the head with scrap jersey knit fabric.

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