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I'm making a halloween costume to mimic the online cartoon character Strongbad (see http://www.homestarrunner.com/vcr_sb.html). I'm making his head out of papier mache using the thick flour and water glue. I have a few questions:
1. How many layers should I use? I'm going to be wearing the head (it's about 34 inches in circumference at the largest point!), so I need it to be relatively sturdy.
2. Is there some compound I should use as a base coat before I paint it?
3. How can I go about sealing the piece when I'm done? I'd like to keep it after halloween due to the massive amount of time I'm putting into this costume. Are there any sealants that are safe for this 'helmet' type creation? I'd hate to be poisoned while out on the town! :?
4. Any questions or generals tips are appreciated. THANKS!
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After seeing the action figure you want to make, I would say you would have to use a balloon armature for the frontal face to achieve the shape. The back could be made of fabric. As far as sealing the mask, many people like to use water-thinned Weldbond.
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Don't worry about the materials. They're not toxic.
Using newspaper, I would say about ten layers for it to last a long time. Using Kraft paper or Bond paper, perhaps six layers, though the surface will need smoothing (sandpaper).
Look in the members for David Svoboda. On his website is an excellent tutorial on moulding face masks, using pastry dough. It's worth a look. 
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Thanks for the info!
Anyone have suggestions for the basecoat? And what type of paints I should use (acrylic, etc.). Thanks!
And just FYI, I'm making the mask entirely around the balloon. It's 360 degrees of Strongbad! 
I'm going to engineer a way to get my head inside of it. I know I'm creating more work for myself, but I'm sure the finished product will be worth it.
I'll try to post pics once my costume is complete! 
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You're probably going to have to use some type of acrylic. Gouache/tempra/poster paints are probably not good for a costume because they are not sweat-proof.
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