What you need is salt dough. I don't have it but there are countless sites on line with the recipe. This is much like play dough that you mold and bake in the oven or microwave. You can pose characters by stuffing parchment paper around the dough while they are baking or use things that you can find like spoon handles.

This may be a wild idea, but I'll throw it out there anyway. How about using that expandable foam that you use to fill in gaps around your house. You might try to form it over a balloon like you do paper mache. Or you could get a face mold and spray it in there.

I am probaly going to make my own moldeling clay. I think I'll try baking them and attach them to a cloth head with holes that I'll pucnh in around the face. It's funny you suggested the spray foam, I bought some last year for a Christmas project and couldn't remember the 'idea' I had. Sooo many ideas floating around up there. LOL. Thanks for the imput.