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Now we're almost done. Over to the bandsaw to cut them out, and then you need to round over the front.
To do this I was using the rotary sanding disk on my sander and just spinning at against the disk at the same angle as the cut on the bottom of the chin. The reason I have a flat section on the head is to make it easier to drill. When you sand the head, leave a flat area big enough to hold the nose grommet.
Then I was removing some of the tail stock on the belt just to slim it down a bit..
From there its basically thru drill, cut the lip slots on the table saw, and then some hand sanding to clean any rough spots from the router and from the rough sanding on the belt/disc sander.
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