Borderlands Psycho mask sculpt

[Gombabomb]

First time sculpting a mask with clay... just started working on it a couple nights ago after getting some face forms and a brick of plasticine which I am enjoying working with so far. Can't wait to get it molded and cast.

Really rough/far from perfect but off to a good start. Top photos are some initial progress and the bottom ones are where the sculpt is currently. First, marked/cut up one mask blank to a better shape and stacked it on an unmodified form so it would be sturdy enough to sculpt over. The face forms I found actually fit well-ish so just doing a thin coating of clay for areas that aren't built up... want it to have a more fitted appearance.

Most of the sculpt so far was just adding clay to cover area and get the basic shape. Used cut off end of a paper cup as a placeholder for the filter/fan since it's about the size I want to build it. Changed some shapes, made a printed ring for the filter housing, repositioned it, put on some plastic bits to see how they look (wrong placement). Then adjusting/reshaping some areas and then that's where the sculpt is left for now.

Most notably need to change the shape of the nose/space between the filter since it's off. Not right from the front and too snouty from side... everything else needs serious adjusting too but that's first. Once the basic form is there I'm going to work on the details and stitches.

How does it look so far?

 

[Vilhouse]

Awesome nothing more to add

*Well there is something to add: I will rework my BL psycho mask too since there are so many great masks being created at the moment

 

[Chris Shirrell]

It looks like from what I can see of the game model and from the promo pics that that areas circling the eye is actually flush with the mask. So it seems that the itself is supposed to be sunk in from the rest of the mask (someone correct me if I am seeing this wrong). To fix that you would have to layer up the rest of the mask a bit. That might make that nose space fit right. However, you would probably have to find a way to make the mask fit more proper with some padding if you cast it.

Also the filter hole might need to be shrunk a bit to get the defining jaw line.

Looks like a great start though.

 

[Gombabomb]

Awesome nothing more to add

*Well there is something to add: I will rework my BL psycho mask too since there are so many great masks being created at the moment

Ha. Thanks! Took a look at the thread showing off your mask. Looks great, especially the LEDs. You going to modify it or start fresh?

It looks like from what I can see of the game model and from the promo pics that that areas circling the eye is actually flush with the mask. So it seems that the itself is supposed to be sunk in from the rest of the mask (someone correct me if I am seeing this wrong). To fix that you would have to layer up the rest of the mask a bit. That might make that nose space fit right. However, you would probably have to find a way to make the mask fit more proper with some padding if you cast it.

Also the filter hole might need to be shrunk a bit to get the defining jaw line.

Looks like a great start though.

Yeah. Supposed to be a frame around the lens which is sunk into the eye socket. Wasn't too interested in trying to get that spot-on... decided to design and print up some basic lens frames to sculpt around. Got some pics of the progress coming up soon.

As far as padding ideally would like to sculpt the rubber lining separately and probably cast in dragonskin or ecoflex. Have some trial size containers of those that I want to play with. The lining would have just enough extra surface area to adhere to the edge inside of the mask... like a gasket sort of deal. Don't know what kind of adhesive to use, might end up drilling holes and stitching around the edge of the mask but I don't know if that would actually look good or not.

Hadn't sculpted the jaw yet in those photos but after sculpting it looks like the angle of the filter might need to change more than the size or position. Eh. I'll figure it out eventually.

Thanks for the input!

 

[Gombabomb]

Here's the current status... and a comparison haha. Can't really see a lot of difference since the first photos, but I think I made some kind of progress.

Added the lens frames and resculpted the eye/forehead area. Got the nose bridge flattened out and the angle a little better. Started trying to get the squared shape of the sides/jaw. Too square... needs to be long instead of wide. Going to lengthen the sides of the mask (sides should end much closer to the ear) but the form has flat edges... will figure something out. "Leather" piece not sculpted on the chin yet. Think that may be sculpted separately with the lining and cast in rubber to make the mask fit more comfortably. Just looking at the photos, one of the lenses is noticeably higher... gotta fix that now that I notice haha. Angle of filter needs to be changed... tilted downwards I think.

Aaand the reason I sculpted on a cut up a blank and put it over another form instead of sculpting directly on one form...

Can definitely see that the jaw is way too wide when worn. Got a good idea of how much to extend the sides when I figure out how to. Should be easy to reshape the jaw and get it looking right then.

Still a lot of work to go, but getting there!

 

[Gombabomb]

Made even more progress. Think it's finally starting to look closer:

Reshaped and moved things around... Top two photos are before chin piece was added and the temple lines were changed. Think I got the profile of the forehead/brow better but eye sockets could be a little more pronounced around the lens frames. Area around the filter is finally starting to look right. Something about the cheekbone angles look off still... maybe just because the stitched striping is missing. Jaw is still pretty broad, didn't do much with that yet since I still need to lengthen the sides.

Is it starting to look right yet? Eventually I can start to add the inverted V and stitched striping...

 

[BondEffects]

hi mate. i have got exactly the same project at the moment. this looks great.

- - - Updated - - -

hi mate. i have got exactly the same project at the moment. this looks great.

 

[Gombabomb]

hi mate. i have got exactly the same project at the moment. this looks great.

- - - Updated - - -

hi mate. i have got exactly the same project at the moment. this looks great.

Looks good! Have you made the mold yet?

 

[Gombabomb]

Rrgh. Was taking and editing photos when suddenly camera card gets a critical error and dumps everything... so there go my unsaved progress photos.

Uh. Was going to post photos of the last few things I did but... anyway. Started work on the filter fan bits. Made something that'll work for the small/outer/center fan. Need to cut it down a little since it sticks out too much, but it's a good start. Got the sides extended with a spare mask blank and my trusty stapler. Lightly applied some very basic V lines and that made it easier to see what was still off so I fixed some weird angles.
Got some new mold rubber and going to get started slopping it on and it might be ready to slush cast tomorrow. Yeah!
Going to take off the stripes though since they were only put on lightly as a guideline. Want to sculpt them onto the first resin version then molding that one to use for future pulls. Think it'll be easier for me to do it that way/less chance to screw up haha.

Managed to rig up some straps so I could get a quick pic of it on before I start molding...

 

[Gombabomb]

All right! Update, but no photos this time... not much new to see.
Had a lot of trouble finding materials for the silicone mold's shell. Used plaster first but did not account for some undercuts so had to break it off. : / Decided to go with expanding foam since there was half a can kicking around on the shelf. Not super hard stuff, but keeps shape well enough for slush casting and is easy to remove from the mold. Got a very thin first cast in smooth cast 300 just to see how well it translates to resin/how well the mold worked. Process went well, but can see a lot of things I could fix in the original sculpt that would make it come out a lot better. This was a test mold anyway and I learned a lot from the process since it was my first time doing brush-on silicone and a shell...heck and sculpting a mask too. Now to smooth out the sculpt and fix some of the spots that I wasn't happy with in the first cast. Actually really excited now.

 

[TymanRoach]

Awesome sculpt man! I'll defiantly be keeping an eye on this thread. :thumbsup

 

[Gombabomb]

Awesome sculpt man! I'll defiantly be keeping an eye on this thread. :thumbsup

Thanks! Been a fun and challenging project so far. Got some updates comin' up.

 

[Gombabomb]

Every time posting new progress photos it feels like they look exactly the same ha ha. Hopefully not this time! Definitely looks like it's on the right track now...

Made a lot of changes to angles/proportions and started trying to smooth with rubbing alcohol. Lens frames and filter ring were just put back in for photos so if they seem to stick out too much that's why. Not going to mold the thing with them in again since it didn't go well the first time. Pretty soon going to make another mold then start in on sanding away some material on the cast to get indents in a few places where the form sculpted over was too round. Then the stripes/stitching get sculpted on once the shape is right. And the chin piece and rubber edge padding will be done separately.

Hmm. image isn't showing up. Boo. : (

 

[Gombabomb]

Two weeks since last update? Wow. Doesn't feel like that long. Just started working on it again a few days ago and got to the point where it looked done enough to make another mold.

Test cast from the previous mold:

It ain't pretty. Didn't realize the mask blank under the sculpt was warped/skewed a little when I glued it down before molding also the mold itself was very messy. The silicone seeped under the lens/fan rings and made a lot of weird flashing in unexpecteed places... all in all turned out kinda wonky. Learned a lot from the process at least, since it was my first try. Half-assed paint job was to see if my paint would work on this resin without primer... much to my surprise it stuck without issue so painting the next cast will be way easier than imagined.

Re-sculpted a lot since I wasn't happy with it... think I finally finished. Looks good enough to me. Took out the lens frames/fan ring to avoid issues like before.




Making the mold:


First coat and finished mold made with Rebound 25

Having trouble with the mold shell at this point... Decided to used spray insulation foam again but ran out and had to get a different kind. The other stuff was soft, but still rigid enough to hold a good shape, but this stuff is really spongy even though fully cured.
New foam


First try mold with old foam:



The idea for this try was to use the foam between the mold and a plaster shell, because there are a lot of undercuts/odd shapes that would make the plaster shell impossible to get off without breaking if I plastered right on the silicone (already made that mistake on the old one). Any suggestions? Going to peel the stuff off and try to find a can of the other style foam since that at least got it to the point where I could start slushing before...

 

[Gombabomb]

Sooooooo... managed to peel off most of the foam except for a thin layer. Ended up having to remove the mold from the sculpture to get the stuff off. Immediately regretted that decision. Was able to get the rubber back over everything but doesn't stay very flush to the surface of the sculpt underneath in the more flat areas. While it was off, noticed some of the high points were very thin so decided to add another coat of rebound to cure overnight. Filled in some of the problem undercut areas, but didn't stay on the high points so those are still thin.. definitely understand now why all the tutorials recommended/involved using ThiVex/thickener during the last leg of the process. Running into a lot of dumb issues because I cheaped out on that part. Gotta get some of that stuff so I can do the final mold right.

Anyhow, can't readily get the first kind of expanding foam used. Next idea is using silicone caulk to make a somewhat rigid but still slightly flexible one-piece shell (like the original foam one, was one piece but flexed a little... just enough to remove the cast easily). Any input/suggestions/warnings on going that route?

 

[BondEffects]

hi mate. i just finished this exact project. i used a repsil e-30 silicone and a [plaster bandage shell. but we both have different sculpts. so i would recommend a fiberglass shell. i cant claim to be the most experienced mold maker as i am only 15. but a fiberglass support shell has partial movement. if you can, get a thickener and fill in those undercuts, it will make your life a hell of alot easier with a plaster bandage shell. let me know what you think.

 

[Gombabomb]

Nice! Going to update your thread with some photos soon I hope? Seems there are at least a few others with the same project too, which is cool to see.

Have a pack of plaster bandages that I was planning on using, but again there are some shapes and angles that just wouldn't fill in with the unthickened silicone that would make the plaster nigh impossible to remove. : (
Doesn't look like any local places carry the more specialized smooth on products like thickeners, only basic silicone and resin kits. Went ahead without it because I was being hasty and didn't want to wait for an online order to arrive... learned the hard way that cutting corners just makes more work in the end ha ha.

Thanks for the suggestion! Didn't know fiberglass would have any give at all. hunh. Interesting.
Never worked with the stuff before... don't have very much space to work or even store new materials. Just trying to go with what's already on-hand for the most part. Out of my element with new materials for this project to begin with haha. Fiberglass'll be a thing to learn for something else down the road... got a friend who's set on doing a Space Marine soon.

Thinking that maybe I could use a small amount of silicone caulk to at least fill the undercuts/smooth out the angles since that is the major issue holding things up. Once that's taken care of, a plaster bandage shell should work without issue... Was your plaster shell in one or two parts?

Quick edit:
Okay. So. One $3 tube of pure silicone caulk later, it looks like it'll be good to go. Gotta let it cure overnight and then some but it should be plaster-able tomorrow at some point.

 

[Vilhouse]

Looking awesome so far!

I feel your pain when it comes to molding. Messed up the first mold of my new psycho mask, but still was able to pull 2 casts.

 

[Gombabomb]

Looking awesome so far!

I feel your pain when it comes to molding. Messed up the first mold of my new psycho mask, but still was able to pull 2 casts.

Thanks!

Tough to get the hang of at first... what seemed like little mistakes or "eh. it'll be fine" type things made a lot more work to fix or get around than imagined. That's great that you managed to get two usable casts at least.

 

[Gombabomb]

Worked on it all day yesterday... lots of good progress.

Silicone caulk reinforcement on the mold ended up working great... made plaster bandage shell the next morning. Only two layers so it's sturdy but has just enough give.


First layer of resin, very excited seeing it form as it was being slushed:


And here's the first pull after eye sockets were cut out. Was a very thin film of resin there... able to slice out with a scalpel:


Started working on making the cheek area more concave. Used my trusty chisel (only work with hand tools):


Test from the first mold on left compared to the current pull... can hopefully see the changes in the sculpt:


Sand, bondo, repeat... then painted and sanded again. Not perfect, but smooth enough. Starting to look good at this stage:


Painted mockup of where to sculpt the lines... looks close enough:


Outlines as a guide for adding clay:


Laid down lines of hotglue along stripes for to give clay something to grip... using paperclay that happens to be red:


Clay dried overnight, bonded to surface nicely.

Next onto rest of lines, then sanding to a much lower profile, etching the seams and adding the stitches. Going to fill in some spots around the nose since I'm not entirely happy with that... then it'll be time for making the FINAL mask mold. Made this way more complicated than necessary ha ha. Have to sculpt the chin piece and edge padding and get them prepped for molding and casting in rubber... got an idea how to do it. Think it should work. Mmmh. Then there's the fan that still needs to be made, and the lens frames/fan ring need to be built up and beveled slightly at the edges... still a lot to go but it feels so close and is starting to look like it's getting there. Having way too much fun with this.