I had purchased a replica baseball batting helmet at the 99 cent store with the idea of cutting the bill off and using it in my Mandalorian helmet. After cutting, I realized it would be a perfect base for the crown of my Tusken. Here's where I started.
I wanted to try using more "found" items, and also was after a "different" twist on the normal costume (read; I'm cheap). I settled on using brass garden hose nozzles as the horns and tusks. They worked great! I did hacksaw off the threaded portions, leaving only a flat base to attach to the mask. Using JB Weld, this was easily accomplished.
I needed the face portion of the mask. I used a styrofoam wig head thing (?) and bulked it up to my head size with crumpled newspaper and a couple layers of papier mache. On this, I sculpted/poured a plaster rendition of what I thought the mask may look like. I then covered this with about three fiber glass and resin layers (only one layer of cloth). When cured, I busted the plaster out and was left with a near-perfect-fit-to-my-face mask. This, I fiberglassed to the batting helmet.
