The head is finished! Here are the work in progress shots for him and some of your questions answered.

Materials: resin canine blank, custom jaw set, tongue and blank LED eyes from Dreamvisioncreations. Apoxie sculpt, elastic, computer fan and battery pack I salvaged, reflective strips, paint, fabric, wood glue, hot melt glue gun, pins, needles and thread, cling film/duct tape, foam, sharpie, clippers, scissors, scalpel and slicker brush.

1: character concept from an old ref sheet of mine. Materials ordered.
2: blank arrives, I sand it then attach jaw set and fan. (Oh look it's me *cringe*)
3: paint and create eyes, glue them in. Test LEDs. Paint nose and seal it. Add elastic.
4: Carve foam and attach to give him his characteristic face shape. Carve and glue on ears. (Getting a 2nd degree burn at this stage is optional!)
5: create duct tape pattern, draw pattern, colour, fur direction and fur length into pattern.
6: Cut out pattern, cut darts and start cutting the fur and pre-shaving it.
7: Continue cutting fur, sewing darts and checking.
8: more shaving, pattern all cut and layer on head.
9: Lasts bits of major shaving, muzzled sewn, final check of pattern.
10: whole pattern hand sewn together! Hidden zipper in hood installed, ready to slip over head.
11: Pattern attached and glued onto head. Final bits of shaving done and a genial vacuum! Ear tips coloured.
12: markings brushed on, scar cut and painted, general tidy up.

Middle: There you have it, Red Baron (aka Arrow Stryker) wearing his signature bandana looking badass and ready to wear!

Overal verdict: I'm pretty happy how this turned out, it's my 2nd head I've made and already a gazillions times better than the first one I made about 6 years ago. The YouTube videos by Dreamvisioncreations were invaluable! Thank you!
Vision is good and the fan makes it much more bearable. The jaw responsativity needs a little tweaking but all in all I'm happy. Now to make the rest of the partial before his debut!