The Crossroads of the Aether
Dreizehn (formerly known as the Coin-Operated Boy) is in need of some advice...he wants to create something like the ork "gob" (from Warhammer) but isn't sure what the best materials to use might be, or how to go about drafting this. This is the reference photo, though he'd like it to be more fearsome and industrial/Dieselpunk in appearance.
We'd probably either rig up some sort of device to hold it to his face or use medical adhesive, though depending on the materials used, the adhesive may not be strong enough. Once attached, it should sit against the lower jaw/chin area.
I haven't the faintest idea how to go about creating something like this, so I'm turning to the talented makers of the Empire for any advice or tips.
Or you could go with the Retainer/Headgear idea. A strap at the back of the head to support the apparatus. Or, or, and I am just saying, OR, you could use a modified "grill" and sort of hang the prothesis from the lower front teeth using 2 or so rigid wires to bridge the lip. This would be only slightly more annoying than a few lower lip peircings for the wearer. Remember to consider your materials when constructing something that goes in the mouth! No one wants to become a drooling vegetable as a result of inadvertent lead poisoning.
If want to use something a little heavier, like leather or metal, I would suggest using leather straps to hold it in place. The jaw is basically a variation on the respirator facemasks that are so popular in the steampunk community. One strap would be low, near the base of the skull, and the other would be higher on the head to keep it from drooping downwards.
If you can find a tutorial on making a respirator mask, you can see how to attach the straps.
If the straps are objectionable, You can try to camouflage them by either covering them or making them blend into his hair or other headgear. The other option is to play them up so it looks like the straps are permanently attached. Perhaps you could decorate them so that they look like they are bolted directly into his skull.
You may also try a small piece of 3 inch PVC pipe, which is strong, light, and very durable. It can be heated with a hot air gun or popped into the oven to soften it, then it can be bent to match the chin of your hubby. NOTE! use caution and wear some heavy gloves AND DO NOT PRESS THE HEATED PVC TO HIS UNPROTECTED CHIN! Wrap his chin in a damp wash cloth and then a piece of folded cardboard. This will or should protect him from the heat while the warm plastic is shaped to fit his chin. After it is shaped then do all the detail cutting because if you do so before the center point might move and throw off all your marks. Experience talking here.
Coupling this to the sugru which could be used for the details might provide the ideal way to make what you need.