You dont need a balaclava to have a moving jaw, all you need is a hinge mechanism or elastic. What you can do is cut out the jaw (not just the chin, think about how your mouth moves with the cheek space too), measure out the length of your elastic and hot glue the elastic to the inside of the head and tightly stretch it so you dont have slack on the bottom jaw and glue it to that. Be sure to carve out a pit inside the head where the jaw goes so your jaw doesn’t recede into your head and look strange.
You can still attach it via elastic straps, but you'll want to reinforce the foam first somehow, like with a layer of fabric. It helps to distribute the force better, so the foam won't rip away from the elastic.
The most secure way to do this would be to sew the end of the elastic to a patch of fabric, and securely glue down the patch to hold the elastic in the right position, inside the head.
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You dont need a balaclava to have a moving jaw, all you need is a hinge mechanism or elastic. What you can do is cut out the jaw (not just the chin, think about how your mouth moves with the cheek space too), measure out the length of your elastic and hot glue the elastic to the inside of the head and tightly stretch it so you dont have slack on the bottom jaw and glue it to that. Be sure to carve out a pit inside the head where the jaw goes so your jaw doesn’t recede into your head and look strange.
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The most secure way to do this would be to sew the end of the elastic to a patch of fabric, and securely glue down the patch to hold the elastic in the right position, inside the head.
You may also want to make a liner for the inside of the head, for comfort and/or aesthetic reasons. Your head shape looks like it would be relatively easy to pattern on the inside surface and then you'd never have to look at the orange foam again!
Matrices' liner tutorial: https://pupdates.matrices.net/post/159292227448/heya-so-i-was-wondering-how-exactly-do-you-finish
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