Here's where he's at now.
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Plaster time! I started making the mold a while back.
First the mold walls built around the first half of the sculpt...
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Then two brushed on layers of UltraCal-30 (actually, the picture is only of the first layer, but you get the idea)...
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Then a thicker layer...
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And an even thicker layer...
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And then I ran out of U-30. I had to order some more from MonsterMakers.com.
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I saw this nifty little trick to make a flat surface for the mold to sit on in Lee Baygan's book.
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It worked out pretty well.
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Here's the underside with the escape holes modeled in (before I cleaned up the edges and keys with a dremel).
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I finished the second half of the mold a a few days later, having coated the the exposed U-30 of the first half with vaseline. It's about four layers of plaster, a layer of burlap soaked in plaster, then another layer of plaster.
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I managed to separate them after a half hour of shoving pliers and paintbrush handles into the escape holes...
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Then I spent an equal amount of time trying to get the skull out. I ended up working the jaw off, then using the PVC (which was screwed on) as a lever to work it free...
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Finally, I cleared out the plaster (which came out very easily because I sealed it)...
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I think it came out pretty good. There are some imperfections which (I hope) I can easily clean up, but overall I'd say it's in pretty good shape.