I brazenly stole this recipe from terd123. After boiling Leatherface's head, I pulled off the mask & hair. While I didn’t need to worry about recreating the countenance of Michael Cerveris aside from his chinny-chin-chin, I had to build up a cranium before I could put a hog mask around it.
His mask began as a Safari Ltd. boar. I decapitated it & sliced off the jaw with a hand saw. The inside of the pig head was gutted with a motorized grinder & further hollowed out with a motorized sander. Additional delicate surgery was done with X-Acto knives. The eyes were drilled out then sliced larger to accommodate the human eyes. Upright ears were bent into position. Straps were made from clear rubber bands.
After slicing off the bracelet, Pyg’s gloves were cut from bag of taco pads & slathered in glue & spackle. Leatherface’s necktie was snipped off & reformatted into an oversized bowtie. Two cleavers & a knife were crafted from wood & plastic.
The new apron straps were made of French Historex tape, which isn’t actually adhesive, from a vintage military model kit. The handy-dandy knife pouches were crafted from cardboard & glue so he can tote his accessories around. The towel was cut from a napkin. I curled the belt ties in the back to resemble a literal pig tail as on the show.
Additional photos & insight are on my WordPress blog, Matt The Catania.