Make art out of plastic

I'm making a sculpture for the upcoming dorkbot "Strange Things" art show here in Seattle:  http://www.dorkbot.org/dorkbotsea/events/pdstwe3/

I'm going to be projecting words on to resin heads, so I had to make them.  Oy!!!  It's an involved process, because I was trying to make a head inside a head: so sculpt head out of clay, then do plaster mold, then sculpt 2nd head out of clay on top of plaster, then do silicon on top, then plaster over silicon (to help it retain it's shape), then turn over and do silicon on the bottom (so it's like a rubber clam shell around the form), then take out the clay/plaster form in the middle, then pour in the resin.  See pic with all the layers.

Here is the 1st resin head.  I'm making three of them.  Needs sanding, buy you get the idea!  Can't really see the head inside the head as much as I liked but you can see the ghost of it sorta.