Since all of the DIY Sabertooth masks are complete i wanted to write about a recent thing i tried out! The resin i use for my masks is heat sensitive which is great for those who need to custom size their mask using low heat. However, it sort of sucks if you plan to costume in a hot environment or hang up the mask only to see it sag a bit if your house gets warm. So how to stabilize the mask once it's sized?
A friend of mine who is a pretty cool artist turned me on to Smooth On's Free Form putty. It's much like other epoxy puttys that you simply mix equal parts of but it's really lightweight while being very very tough! I just used some to coat the inside of some cast armor resin parts for a costume. You have to work at it a little since it doesnt stick to surfaces as well as epoxy putty but it will adhere and stay once it cures. I smoothed the surface of mine with water and a large cheap brush so keep everything comfortable to wear. You dont have to use a thick layer for it to be effective since it cures so tough. This would be a great way for DIYer's to toughen up their own masks with an inside layer of Free Foam. It can be sanded too! Not %100 sure on drilling but i assume it would hold up.
As a sculpting clay, Free Form is a little tough to work with since it's a little crumbly when you first mix it. But once curing starts it may get less crumbly, i havent tried it yet.
I hope this helps! For more hints on mask finishing check out my other hints.