So, here's a few pictures of where we stand.
Picture 1: The mold is prepped for mother molding by cleaning it up with some alcohol, leveling the bottom and gluing to a non-reactive surface.
Picture 2: A clay wall (WED clay) is added to make a partition for the PlastiPaste mother mold. At this point, the half to be molded first is waxed for easy release. The base is also waxed for a flange.
Picture 3: The side view of the wall. The supports are behind the all and you can also see registration keys in the clay for proper mother mold alignment.
Picture 4: The first coat of PlastiPaste is applied. This stuff heats up as it begins to kick, so it gets a little warm to the touch. Sharp edges are a problem as this stuff dries. To cure that, take a paint brush with some 91% or 99% alcohol and go to town. It smooths it down nicely and makes the next coat easier to apply and its also easier on your hands.......no slicing and dicing.
Picture 5. Progressive coats of PlastiPaste are added until we build up to 1/4" to 1/2" thick.
Picture 6: Once sufficient thickness is attained and you've waited the appropriate cure time (90 minutes), you can remove the clay wall and inspect your work. I cleaned the back half and applied a liberal coating of wax and Man 200 mold release (extra step for good measure) and went to town again. I did put in four "pry points" of clay in case I need to coax this open when it cures.
Picture 7: The front half of the mold complete. I'm working on the back half now (3 coats in as I type).
Picture 8: The latex mask I'm preparing for the model to wear under the helmet. This will be trimmed down a specific design of Robin mask. This is 15 layers of black liquid latex. The grey color is from the powder used to render it not sticking to itself during remove from the form.
Picture 9: The mask off the form and ready for trimming and final cutting.
There, I hope you enjoyed the post. I hope to be able to do a first "test" pull tomorrow morning, barring complication............fingers crossed and praying to any local deity!!!
Jesse
. please post pictures when you can... we are all waiting to see this come out perfectly.
