After a short time I realized that I had not built up the foam thick enough in many places. Simple

Once the second coat of foam had cured I went back to the cutting and carving. When I needed
When I got the main lines of the skull formed I removed the scale drawings and used a realistic-looking plastic skull as reference and carved in as many small details as I could.
The mess: The worst part of the carving part of the project was the mess and the clean-up. The bits of foam from the carving were light and wisped around very easily. Additionally the little bits were very static-ey, they stuck to everything. I regularly left a very clear trail of foam bits leading from my workshop, up the basement stairs, into the hallway, across the dining room…
My wife was none too happy about it.
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