I would love to read a how-to. This is the same method that I was going to do as to the build up, but unfortunately I don't have access to a Vac-forming table nor the space to build one.
What I would really like to see are some patterns, because I may just go the route of building them out of sintra or sheet styrene (however doing them in wood would alleviate a lot of bondo or filler) because they are not for a costume. They are for a display that I am currently working on. Thanks!!!