I started sculpting the helmet in foam beginning with the horns. Symmetry is very important in a lot of my designs so I wanted to make sure that the placement of the horns was symmetrical from the very beginning. I started with two identically curved pieces of wire. Then I covered the wire with scored pipe insulation foam. Foam is a great choice for sculpting the core form in if you especially if you intend on leaving the core from inside the finished product as I did.
Spray Insulation Foam Base
The rest of the form was roughed out in spray insulation foam (GreatStuff) and a chicken-wire armature for the beak. Again, the idea here is to keep the materials light and easy to carve down later. Note: spray foam expands a lot! So don’t fill in gaps too heavily and expect to carve the form down later.