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MOCKUP/HEAD:
Sorry, no images of the ¼ scale cardboard mock-up; only the the splayed pieces next to the full sized pieces.
Marked and measured mockup at 1” horizontal intervals. Calculated 4x of measurements and applied to 4 mil sheets every 4”,
The line markers nearer the middle of the head lined up with cut points to create flaps that would overlap. This would give the head it's contours – kind of like really big origami.