I see what you're saying, but if they were to go the Samurai route for a potential costume I still think it would be a lot easier just to use the normal mask design rather than over stylise it to look demonic.
I also wouldn't have it look much like a helmet. Just keep it like a mask, but one that still shares the same material and artstyle as the Samurai armour styled version of the costume.
Though I think you could have something similar to the mouth part of the Samurai mask with the normal Wolverine mask, but have a scene where it gets broken off and we're left with a costume that looks like the classic style yet adapted for the silver screen.
If there were to be any extra flourishes on the mask itself then I'd probably go with something like this.