Hey!! So when I was making my Bill head, I looked at this cosplayer’s awesome tutorial: http://rusharound.tumblr.com/post/102603973293/bill-cipher-build
I used to same materials, so I made it out of painted posterboard, a TON of hot glue, a bamboo rod for support that went through the hat, and a headband glued to the end of the bamboo support. It’s super light weight and because I used a headband to attach the head to me, it turns when I turn my head and generally works really well. Tips I noticed: the posterboard will warp after you paint it, so you have to set it under really heavy books for about a day to straighten it out. If you use a textured rolling brush to paint the head, the light hits it a bit better and it looks more interesting than just matte paint (in my experience). The hat is really easy to make if you use the cardboard from a paper towel roll as the base and then put posterboard circles on each end, a bigger posterboard circle at the bottom for the brim, and then cover the whole thing in fabric (I just hot glued my fabric on). And for the pupil of the eye, I suggest using a sharpie instead of paint because it is easier to see though! Good luck and let me know if you have any other questions!
