Very clean work on those molds. Very professional looking, especially considering you've never done this type of molding before. That's WAY cleaner than I was on my wookiee crap!
Bob, what about the FlexFoam-It series? http://www.smooth-on.com/Rigid-and-Flexible/c10_1121/index.html
This looks similar to what Disney did.
That was always my first concept because of Disney's but the guys at Smooth On really tried steering me away from it for some reason. I think they felt it'd always have a pourous surface. The one's from Disney are a different kind of foam that is baked to cure. Its apparently different in that it dries with a smoother surface.
I do have the FlexFoam for inside though... should be interesting.
Chris, I bought some Thivex but didn't use it just because it was already pretty thick and oozy. Are you suggesting actually keeping the mold open, layering all surfaces with the thickened Thivex stuff and then closing it and sloshing around the regular stuff to fill in the seem areas?
I envision using polly fill to fill in the lekku but also some of their memory foam in the top of the head area. I'm still trying to wrap my head around how to do that without tons of difficulty.
IT FITS! This is just the first proto-type so to speak (full of holes and thin spots) but its basically proof of concept! Right now it's just stuffed with plastic bags to show what it will look like with the foam inside.