Looking at pics of Dick Warlock …While his face is not as narrow as Nick Castle it is still a thin face…Was the storing the mask in a shoebox or whatever cause it to look fat ?
I highly doubt it … While his face was not really super wide, it is much more square than Castle’s …Mix him having a wide jaw and wide temples with the mask being pretty small to begin with & you have the way it looks…
50-oNe-50
Exactly. You have to remember the 75 Kirks were not very big at all. My Shatner is the same size as a 75 Kirk and let me tell you what, it’s pretty small. I would consider myself to have a small head and I struggle to get it on. It wouldn’t be any surprise if someone with an average size head/face put the mask on and the mask looked stretched and distorted. It wouldn’t take much at all to get that affect.
Also in HalloweeN They used a lens that streches vertically in alot of the Myers closeups (Phone scene for example) In HalloweeN II They did not use that len. Another big thing that changed the look of the mask was the fact the mouth was tapped shut and the neck slit was closed when Warlock wore it, so it contorted too his face alot more. Hope that makes a little sense 
-KennyD
Dick weighed about 200 lbs in Halloween II, at 5’10-5’11 that’s fairly heavy. He soon dropped down to about 170 but his weight at the time made his face a bit fat and that (along with what KennyD already said) is why the mask looked like it did in Halloween II.
Dick Warlock at the time of Halloween was a pretty big man he did have a pretty wide face, not to mention the mask had also been under Debra Hill’s Bed for quite sometime now…
I think getting all that hair into the mask gave it so features as weel. Dick had very thick hair back then.
I thought Dick was fairly short like around 5’9" which is why he wore lifts in Halloween 2. He also looks like he weighs much less in Halloween like around 170lbs. If you look at the scene after the Elrod house when he is walking on the lawn he looks very skinny.
I think that is one of the biggest things that gets overlooked when people spend tons of money trying to create the perfect Halloween costume from the first movie. Nick Castle was probably 6 feet tall and very skinny. People will spend up to a thousand dollars on a mask, spend days weahtering coveralls, and make sure they track down the perfect jungle boots for the costume. Yet if you don’t match size-wise to either Castle or even Warlock it will always look off.
it wasnt just the roundness of his face but the circumference of his head that added to the distorted shape of the mask.