Approx. 20 layers of styrofoam were cut by a CNC router using a 3D model from Thingverse: http://www.thingiverse.com/thing:25189.
Each layer was cemented together using adhesive spray.
Ethan and 2/3 of the head.
Additional layers were added under the face.
A wooden base was built to replicate the one seen in the original photograph.
Additional green screen tests utilizing the head.
Mario interviewing the head for unused footage.