The play is a comedy, so Black Death had to be intimidating and cartoonish at the same time. The mask is carved from a block of polyethelene filter foam which is set on top of a welder's mask. This made the figure taller than other characters on stage, and permitted the mask to be swung up quickly so that the actor inside could deliver a punch line.
Photo by Arlo Bryan Guthrie. Modeled by Re'chard Atwater.