I made a stylized orangutan skull using 85 foamboard cross sections, metal welding rods and polyester filler. The original skull (top right) took around two months to build up, sand down, fil up, sand down again, primer coat, sand to 600 grit. Then… it was time to do the jaw. Same procedure. Then I used water based clay to make two-piece silicone molds of the jaw and the head. When it was all done I poured polyurethane into the mold and made copies of the original sculpt.
This was before I had a 3d printer, which could have saved me hours and hours of work. It still was extremely gratifying to pull the copies out of the mold. I spray-painted them using car paint.
I gave copies to my friends (graphic designer) Raphael Bartels and (graffiti writer/designer) Shoe so they could add graphic elements to the skulls and they looked great.
Marc Sokpolie 
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