The photos in my tutorial at http://www.fursuit.de/ are from several fursuit heads and my methods changed over the years. Some people are confused by this. Last week I got the urge to build a new fursuit head (while I watched Qarrezel working on Fisk's cheetah mask - fursuit making can be contagious).
This time, I also made pictures of the intermediate steps that I have only mentioned in the past. The head is not finished yet - right now I'm waiting for the painted eyes to dry.
Bend an aluminum profile (20x3mm) to fit on your head - this is the basic structure on which the plastic mesh will be attached. It should sit very smooth on your head - from the back of the head to the forehead.
Attach the plastic mesh with elastics. Notice that the elastics do not cross each other on the insides of the head.
Every cut in the plastic mesh should be smooth - remove all sharp edges. Cut the mesh on the sides to the middle.
Build a shape that sits comfortable on your head - start with the mesh stripes on the ends. Make shure the ends of the cable ties are always pointing outwards.
Close the holes and cut the mesh if there is already enough material.
Make sure the mesh does not reach your ears.
Cut the mash for the sides of the fursuit head.
Bend the sides round and use cabel ties to fix the position.
Attach the sides to the head.
Make sure that there is enough space for your ears in the sides - and maybe a 9V batterie.
Cut the mesh for attaching the eyes and bend it.
Find the right place to attach the eyes. Find out where your eyes will be. If you want to wear glasses inside the fursuit head leave enough space for them.
Draw a circle with the same diameter as the plastic eye and draw a straight line thru the middle.
Bend aluminum profiles (20x3mm) - these will hold the eyes - the eyelids go between the eye and the profile.
Attach the mesh over the eyes and use the aluminum profiles to bend it in the right shape. Reinforce the plastic mesh with polycaprolactone (you could also atttach the profiles directly to the mesh).
Make eyelids with polycaprolactone.
Attach mesh below the eye.
Attach the muzzle and test the eyelids.
Check whether there is enough space for glasses.
Attach a leaver to the eyelids and bend steel wires to attach them (to have more room for the glasses).
Make shure the eyelids move smooth - change the holes if they scratch on the plastic eye
Cut a form out of thick cardboard that fits to your chin.
Cut the outside of the cardboard so that it fits in the upper jaw.
Bend a aluminum rod to the form of the lower jaw - based on the cardboard template. Cover the front of the lower jaw with polycaprolactone.
Make a base plate for the teeth in the upper jaw.
I tried to list all the important steps - some generic parts (like: how to work with polycaprolactone) are not explained.