I just finished a new mask, it'll debut this Friday night with Black Cat Burlesque's performance at the the 5th Annual New York Burlesque Festival.
Some photos of the process:

Wire framework of the head, made from 14-gauge galvanized wire from Home Depot, with 24-gauge wire figure-eights to tighten each joint.


Double-wide masking tape wrapping the wire, with some balled-up tape to help mold the features----less-messy and less-smelly to work with than papier-mache



Layers of acrylic paint over a base coat of Mars Black