not to steal Ron's thunder...but A/B foam is a two part polyurathane foam that expands/hardens when you mix them together. Check out
http://www.smooth-on.com/foams.htm

I bought some of their samples to test filling masks (bucky lids). It works well. The low expanding foam didnt fill out the mask and medium expanding did with alittle streach of the latex.

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Thanks Randy,
he's right, smooth-on is the place to get it. I actually get mine froma place called SPS, but they will only sell to prosthetic or orthotic labs, so unless you work in the field or have a friend that does you will have to go with smooth-on. Good thing is that it doesn't need special shipping.
To cut down on latex stretch, only mix enough to fill 1/4 or the mask and let it expand. When hard, fill up another 1/4. I've found that only 2 - 1/4 fills will allow it to totally fill the mask. The stuff I use expands like 200%.

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Thanks everyone for the helpful tips. If anyone else has experimented with other methods I, and I'm sure we, would love to here about them. That a/b foam is a little pricey(of course, I don't really know how far any certain amount of a/b will go). Also, does a/b harden to the consistancy of a styrofoam wig head or is it more flexable? Could it be used in conjuction with a styro-head or would it destroy the styrofoam.

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Blah, Blah, Blah, - http://blogcrypt.com/MrUnpleasant updated - 09/04/07

Something Unpleasant This Way Comes!

Found this website tonight

http://www.geocities.com/themaskdr/index.html

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http://halloweengallery.com/index.php?cat=10049

For some of my static and pneumatic props where I need to fill out an old mask, I use wig heads and plastic bottles wrapped with shipping bubble wrap. It's cheap and does the trick.

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