I still think you need to do the crest with the big wings that was in that book we looked at! Dude, at faire everyone would see you first.
Seriously, when we mentioned paper mache the other day, there's some merit to that idea. If done right, it can be sanded and painted, and made to look like other materials. Example-- my scarecrow's head:
It's cheap and easy. Diluted Elmer's glue and Viva brand paper towels and newspaper. I'm tempted to try it too.