My brother bought a cheap Halloween costume a couple years ago for Frank the Bunny from the movie Donnie Darko. He liked the costume, but was dissatisfied with the quality of the mask. As a (somewhat belated) Christmas present, I made him one.

Base is a total of three blank party masks (two doubled up for the face, parts of a third for the forehead and upper jaw). Ears are based with high-density foam floor tile. Detail modeling is done with Model Magic. Acrylic paint, sealed with Mod Podge. The eyes are sunglass lenses. Total cost of materials ~$60.