Congrats on the marriage and best wishes.
That's really cool how you used a pep as an armature for sculpting. I actually bought some clay a while back to do that too, but I haven't gotten around to it quite yet. Looks like it works great. I'm sure that's probably not new for the folks around here, but you are the first person I've actually seen do it. Nice sculpt too.
Sorry you had some UltraCal problems. I'm not hardly a mold making pro myself, but did you have burlap reinforcement? Usually a good 3-4 overlapping layers, making sure not to have air pockets does the trick. Also, when adding more UltraCal, make sure you don't let it dry between layers or it won't adhere to itself correctly. If you are interested, John Brown at
The Gnomon Workshop - Tutorials for visual effects artists, concept designers, sculptors and comic book illustrators and traditional artists using Maya, ZBrush, 3ds Max, Photoshop and Painter as well as traditional drawing and painting. has some excellent sculpting and mold making DVD's.
I have a hopefully quick question for you.... I'm a big 3D guy and have been doing that for quite a number of years now. This whole costume making thing is new to me, but I'm extremely interested in it. My question is... how much of a pain/learning curve is required to take an object into Pepakura and unwrap it? I would prefer to make my own stuff from scratch, but hesitant about what seems to be a very tedious unwrapping process. -I don't mind tedious work obviously and can unwrap UVs til the cows come home, but that seems more like torture.
Once again, congratulations.