Yesterday I began slicin' and dicin' the urethane Otis casting. I drill small holes around the perimeter of the areas I want to remove. Then I use a pair of small wire clippers to cut an opening on each side large enough to accommodate a hand saw. I use a hack saw to cut the trapdoor in the back of the head. I drill large holes in the eye sockets, then use the wire clippers to cut out more plastic. I smooth the edges of the eye sockets, mouth cavity and headpost hole with a Dremel grinding bit. I also round the edges of the trap door opening. I found that the edges are really sharp otherwise, and as often as I'm sticking my hands in there, it's safer to smooth the sharp edges.
Lastly I use a round Dremel cutting bit to rough up the head's glass-smooth interior so the Magic-Sculpt I use to secure mechanics will firmly bind to the head.
And of course, I sign my work.
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