Sometime ago I came up with a new way to make plague doctor masks that not only made it easier but also allowed me to do a lot more to them; The answer was fiberglass shells.
Using posterboard to make the forms, I fiberglassed them like a Pepakura model, coated them with Bondo, sanded them, and painted them. On some of them, leather plates were added to give the masks more depth and character.
The fiberglass shells also allow me to use lighter weight 2-4 oz leather and to make the mask, then slide a fiberglass shell inside it to support the lighter weight leather and keep its shape without sagging. The results are increasingly impressive.
As the cooler weather creeps upon us I am thinking of doing a run of these this winter… here’s some pics of plague doctor masks from the past few years:
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