Cleaned some of the trimming and filled the ears cut out foam. Added structure (2mm foam) to the chin/throat cover (also extending it) after cutting it out of the cowl. Sadly it doenst look like it will be compatible with the rubies.
The neck piece seemd to not work with just the foam so I extended it using velcro (the other opposite side of the velcro attaches to the main cowl (also gives it some thickness and regitdity).
Glued up the back and backed it with 2mm foam.
Used foam to stiffen the brow area and realized that adhesive Velcro is rigid and flexible enough to thicken the cowl up. I used the soft side for places that will touch skin and the spiky side for the top. Air bubbles can form from the Velcro but they can be smoothed out, or the Velcro can be removed rather easily and replaced to reduce air bubbles.
After a coat of Plastodip, it's done!
Update:
Had a piece of pleather from a Bat-Fleck project I never did, so I gave the cowl another (slighltly more generouse) coat of Plastidip and used the pleather as a textutre. Print lines are still visible, but not as bad in person. Overall, I'm pleased with how this is turning out. Much better than when I first got the cowl.
It is more subtle in person, but at the right light it can get close to these photos
Added some structure to the top eyelids with 2mm foam. I traced the eyes and cut out a brow support. Glued the back of the foam to the brow and glued the top of the eye hole to the bottom edge of the foam. This fixed the drooping eye problem (last to photos).
I also added the Rubies collar as I think it works well.