Wow, so I'm crafting a little bit of our Halloween costumes this year - my husband and I are going as Sweeney Todd and Mrs. Lovett (you can see the process here and here... I'll try to post more pictures tonight). I've made Sweeney's vest and razor, partially made Mrs. Lovett's skirt, made a stuffed rolling pin and cannibalized an old top to turn into hers. Plus I've dyed a LOT of stuff. I think this is pretty crafty. But that's nothing - I mean, nothing, compared to these utterly amazing and fantastic papier mache Where the Wild Things Are masks made by Craftster sjeanette.
She says she used a papier mache base, then painted them with acrylics and used all kind of various things for the details of their faces. And lots of hot glue, which I can totally relate to. Check out her post (link above) on Craftster and see individual pictures of each monster - they're really wonderful. Link
I love what you and your hubby are doing as well. It makes me wish my boy toy wasn't halfway across the country so we could have matching homemade costumes as well.
That brings back memories... in fact, I think I still have that book lying around.