After creating a cardboard head template and testing sensors and hardware in it, metal parts were cut based on what was learned from the cardboard version. The metal parts were then drilled for holes and assembled.A few modifications were made however, such as flattening the chin and simplifying any unnecessary edges. The primary problem with the chin being pointy was that the sharp point could have damaged the parts that allow the head to move. The flattened chin also allows more room for the head to tilt forward.
The metal head proved to be difficult to mount to the wooden axial of the neck. The problem here was a lack of surface area to attach the rotating neck dowel to the bottom of the head.