So there was something that was just not right about the finished Casey Jones mask. I ended up having a friend look at the movie on bluray and he noticed the brow was different. So that meant back into the garage to work out some changes.
The brow was cut in a "V" shape, heated and pushed forward.
Then the back was refiberglassed and more filler applied to smooth it all out again.
A couple more hours and some paint and I was finished... again. I still need to drill the strap hole before molding, but that will come later.