Upholstery foam, 1/2" and 1" thickness

Dark grey fleece

Light grey fleece

Colored fleece (your choice)

Black fleece (for eye detail)

White felt (or color of your choosing)

Light grey chiffon

Black extra bulky yarn

Colored polymer clay (your choice)

Armature wire

Floral wire

Flexible support rods (thin dowels, pvc piping, etc)

Gloss Varnish

Sand paper

Hot glue gun and a LOT of hot glue (contact cement might work as well if preferred)

Sewing machine (for optional detail work)

And that's it! You now have a completed Wiggler Head!

First, I used the 1/2" foam to create a cylinder around the wearer's head, then cut a window for the face and two indents on either side so that it rested easily on the shoulders. The 1" foam can probably also be used here instead, but I figured the thinner foam would allow for more potential movement in the neck.At this point I added three support rods inside the neck, two in the front and one in the back, to keep it stable while working. To form the head, I started with one central strip of 1" foam with an armature wire attached to the interior to hold the shape. The wire ran down the length of the back as well and could be bent to give the neck a more serpentine appearance. I glued on additional strips of foam as shown to complete the head shape and added in more armature wire to areas that needed adjustment or support. By the end the head got pretty heavy, even with all the support, so I added two circular pieces of foam inside the length of the neck to keep it from collapsing. Here's a very rough template of how I cut the fabric, probably not entirely accurate but fairly close. I used two layers of fleece for both colors to help hide some of the imperfections in my foam structure. I glued on the lighter fabric first, leaving some length at the bottom for the "cowl". Unfortunately with the darker fabric I had to make a seam on either side of the head to avoid excess bunching and folding at the cheeks and mouth, but luckily most of it ends up getting covered by the head frills. For the stitch detail along the edges I cut the top layer of dark grey a bit larger in areas (as pictured) then folded it over the bottom layer and sewed it together. I then glued this fabric in place on top of the lighter fabric.For the frills I made paper templates to mock up the correct size and shape then traced and cut the pieces out of felt. In total I cut out 8 larger frill shapes and 8 smaller frill shapes. On half of the frills I glued a bent length of floral wire, then glued another felt frill over it to conceal the wire and add thickness. I also cut 16 small segments out of the dark grey fleece to form the points that attach the frills to the head, and on half of those I added stitching detail. I attached the detailed segments to the front of the frills and the plain segment to the back, then glued all 8 completed frills to the head.The colored fleece circles are also doubled layered. I cut twelve small circles, four medium circles (for the cheeks), and four large circles then sewed them together in pairs. For the black segment near the eye I only used one layer but added stitching detail along the edges. I then glued these all into place on the head and neck.The eyes are made of pre-colored polymer clay (like sculpey or fimo) that I shaped by hand then baked as directed. After letting the clay cool sufficiently I sanded it down to get rid of any bubbling or imperfections then coated it with acrylic gloss varnish.For the yarn, I cut eight even segments then tied the ends off to prevent unraveling and fraying. I glued 6 of these segments along the mouth seam and used two for the eyes, tucking the knots into the button holes then securely gluing the completed eyes to the head.In order to allow the wearer to actually see and breathe in the mask I cut a hole in the light grey fabric where the face window had been cut out of the foam. Between the fleece and foam I then added a segment of grey chiffon and glued it into place (I found two layers of fabric gave the optimal amount of concealment while still allowing adequate vision and ventilation). Finally, for comfort, I lined the interior and bottom edges of the neck with whatever spare fleece I had lying around.