Through my research I found that best way to start a chewie mask was to sculpt it directly to my facial contours in order to fit perfectly. So I needed a life-cast of my head. Not something I could do by myself, and my wife rarely has time to help because she is so busy with work. Fortunately we had a vacation coming up. :) With the help of my wife and her cousin, we did a life-cast of my face on the hotel room floor.
This is the basic process:http://www.rebellegion.com/forum/viewtopic.php?t=18217
I wish I could say my process was as seamless as it seems in the tutorial, but alas, it was not.
My mold broke and I couldn't make another life-cast because the vacation was over. So I ended up sculpting my head by looking in a mirror.
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