Got all the fractured parts repaired today and gave Fawkes a little darker wash to match closer to the 3rd Gen shiny Blaziken's design. Also gave the face itself a matte finish and gave the beak a good sound layer of enamel, buffing it to a shine. It's rather subtle in person, but the texture is noticeable. Things not seen is making the inside of the mouth black (as well as the rest of the interior) and strengthened any areas I could as, from the stories I have heard, a lot of folks at some cons can be rather rough if no fursuit etiquette is known.
Got some very strong magnets to replace the current ones coming and some red felt to complete the tail.
And you were right! This was my second (finished) head. My first attempt was a crappy paper mache half mask I made in a hurry for Halloween that fell apart quickly. I also tried to make a resin base instead of a papier mache one for this mask, but it was too thin around the edges and too thick in the beak. And the jaw was untrue. So I had to revert to cheaper materials. XD I learned my lesson. My first head was the Anime Expo 11 Blaziken, and now that I look back at it I wonder what I was doing with it on in public. The eyes were entirely too small and it was too boxy, and the fur I used for it SUCKED.
The magnets I found were rare earth magnets and might powerful ones at that. I had thought of doing a zipper, but putting one in on both sides would have been a pain and with the head set up I needed both sides open.
And the double-zipper problem is exactly why I went with magnets and a button snap. I didn't want the long fur to get caught in the zipper either.