The way to cast resin masks can be found here. This is the tutorial I use to make resin masks. If you read her artist comments, she answers lots of questions and lists off additional materials, tips, etc. I also have the materials listed (along with links to where to get them) on my mask page. Please look at these links and research a bit before asking me. I can't possibly tell you how in one simple response... its impossible. If you wanna make your own masks, bottom line, it takes practice (sometimes a year or more) and you gotta jump out on a limb both financially and artistically to get started.
No and I never will.
I get asked this more than anything else, and its getting a little annoying. Answer? I don't want to tell you. It has sort of become a "trade secret" among certain mask makers and myself and it gives us the upper hand. I'm a turd, I know. :XD: I will say however, that as far as how to make it, its cast the same exact way the mask is made and is shaped a certain way for good function (nothing perfect, but yes). I don't use elastic, rubber bands, or springs for its function. It's just set against the wearers jaw nice and snug to where it moves as they speak. That's all it is. So just experiment and try making one on your own. ;)
No, I know I used to, but I don't anymore because I want to devote all my time to masks. I also have artwork commissions and I can't possibly handle all of this. Plus, I'm not the best at making any of those items, you'd be better off buying some from someone much more experienced with it.
No, for the same reasons above. I just don't feel comfortable dealing with that kind of stuff. I know several people who are very gifted with full suits that I can recommend you to. ;)