After lots of research I found a really good way of making a decent Rorschach mask. With all the requests for instructions floating around the web right now- I hope this will be useful to someone, somewhere.

1. Take a plain white t-shirt and cut it straight across from arm pit to arm pit.
2. Along the fold, cut it up and down so that it opens up and lies flat.
3. Turn it inside out and stretch over your head. Pull it tight and mark along the back where you will sew it together. (Help with this is good).
4. While it is stretched over your head, also make a small mark over each eye.
5. Now get your design ready. I used a real inkblot (as used in psychiatry). There are links on-line. This is one site [link] but also look for the actual blot pictures.
6. You will want to measure you face so that the design will be the right size. I measured from the middle of the nose to about 1/2 inch past the eye, and down the center of the face from above the eyebrows to the chin.
7. Transfer this onto paper, should look like a cross. When you trace your design, line up the center and the eyes. Make sure that the eyes are covered with black (or else you won't be able to see).
8. Once you ink the outline, tape it to a piece of cardboard. Then stretch the fabric over the board (right side out), making sure the marks for the eyes line up correctly. Tape the fabric down before you start to trace. You don't want it sliding around.
9. I used a technical pen to trace the pattern, and then used a paint brush to paint the blots. The ink spread out a little, so start from the inside of the design, and work your way out. Take breaks to allow the ink to spread before working too close to the lines. Personally I loved the result- it looked properly "blotty". I don't like the very smoothly drawn blots I have seen in some pictures.
10. I dried it with a hair dryer to set the ink. I liked the ink because unlike a sharpie- no fumes, better coverage, nice dark black design, naturally blotty look. Be careful with it though- while wet it can smear, but once it is dry it sets and should not wash out, sweat out, or fade.
11. Turn it inside out and stitch along the lines. I did not stretch it too tight at first, then went back and kept adjusting it until it was where I wanted it. Do not stitch all the way to the bottom or it will not slip over your head. I left the bottom half open, and used fabric glue to attach velcro so I can pull it tight around the chin once it is on. Between that and the ascot it fits great.
12. No need for eye holes- as long as black is over your eyes- visibility is actually pretty darn good.

Using a t-shirt eliminates the need for multiple layers, and eye holes. Once the black is on your features will not show through. Not to mention a cotton t-shirt is not as stuffy as 3 or 4 nylons.