I‘m going to make a hollow cat mask that is larger than a head and would cover the head entirely. It measures roughly 35cm x 16cm. My base is made of cardboard, with a layer of masking tape all over it. I was thinking of using plaster gauze to create the mask because it allows detailing and smoothing out with sandpaper but I am concerned with the weight of the plaster.Is there a lighter alternative that can be sandpapered down to create a smooth surface?
If you are willing to put up with the hassles, you could probably use Bondo but would have to build some kind of base to attach it to - perhaps screening over a form you removed. About the same thing applies to using fiberglass resin over either fiberglass or other cloth altho sanding fiberglass requires lung protection. There are some moldable sheet materials used for cosplay and reenactor armor where the thin (1/8?) panel is soaked, shaped and let harden (the old version of this used acetone - nasty stuff - I am told the new stuff is better) To do a head you would have to do it in at least halves, maybe thirds, depending on how much bending the sheet will take.
The gauze is the same, but it is a luxurious means to buy gauze and you possibly can be combating the folds within the material. You should use any white material that doesn't stretch so much (sheets work, t-shirt fabric doesn't much) but you could purchase cheese fabric at grocery shops (used for filtering jelly for instance, apart from making cheese) and at fabric stores. The expertise of purchasing plaster bandaging is neatness considering the fact that you soak the rolls, unwind them in location after which do rapid smooth up. Utilising material and freshly made plaster requires working particularly quickly and then cleaning up the blending bowl (no longer down the drain) and any drips from relocating the soggy plaster laden cloth to the mildew website online.
