(Update: finished Sith Acolyte V3 and Darth Nihilus masks. See below for production photos)
Avolyte V3 (current)
Acolyte V2 (older):
Acolyte V1 (oldest):
Darth Nihilus from Knights of the Old Republic game:
LEFT: official game art - RIGHT, my finished vacuum formed mask
Original Post with production info begins below:
Here is the mold skulpted out of Bondo. I used a resin thinner to thin out Bondo to make it more liquid (to cut down on the amount of sanding).
The second project is a Sith Acolyte mask from Star Wars The Old Republic game (left), which is still in its initial rough stage! This one I will not be able to vacuum form as there will be too many sharp angles and tiny details (which will not come out well, unless I use an exremely thin plastic). I'll keep you posted!