As expected, the head was the biggest challenge of this costume. I started by constructing papier-mâché around a beach ball. I used approx. 6 layers (probably more) for strength. Once it dried, I deflated and removed the beach ball, then gradually cut the hole to the right size for my head. I then used batting and felt to finish the appearance. I have already been through a few different methods of trying to get it fit on my head for long periods of time without hurting me (as it is a bit heavy and awkward) and I think I've found a satisfactory compromise ^_^

San Japan 1.5

A-Kon