Chewbacca Build (WIP-lot's of pics)

[jweger77]

This is a project that I started last winter. I work a lot 9 months out of the year and I have a lot of free time in the winter. So I've picked it back up again and would like to share my progress. There are many great Chewies out there and I'm going on my own on things. My plan is to create the whole thing from scratch.

I've gotten a fair amount of the suit done. I'm about 40% done with the shirt of the suit. I needed to take a break and do some other things to keep from going insane while latch hooking! Here's where a couple of things are..

Suit

Feet

Bowcaster Test

 

[jweger77]

Re: Chewbacca Build

Lifecasting of the face done yesterday to begin the process of making the mask. Here's a couple of photos of the process. My wife did a wonderful job for someone who's never done this before.

 

[Edwardowan]

Re: Chewbacca Build

This is going to be amazing!!!!! And the documentation of your progress will be legendary if it stays at this level... thanks and look forward to seeing this!!!!

 

[jweger77]

Re: Chewbacca Build

Thanks Edwardowan! I can't promise there will always be a ton of pics but I'll try!

 

[jweger77]

Re: Chewbacca Build

Today's progress... Took the face cast yesterday and fleshed out the rest of the head based on my own dimensions. I took a styrofoam head, cut the face off and attached my cast, then built up the rest of the head with clay. Finally, I plastered the rest of the head. Wooden base of the head is attached to a small lazy susan for sculpting.

 

[SampleName]

Re: Chewbacca Build

I love seeing people build bowcasters. :thumbsup Keep us updated with your progress!

 

[Nynxy]

Re: Chewbacca Build

amazing!! I've seen some great made from scratch chewbaccas and this looks to be one of the amazing ones!!

 

[Waffen Bucks]

Re: Chewbacca Build

Arrrrrggghhhh...Chewie says this is gonna be killer when it's done. Did you have any problems with the face casting? I ask, as i've read on other posts about the plaster becoming too warm when it is contact with the skin (i'm thinking of doing myself in Carbonite) and buring your face etc.
Keep up the great work!!

 

[lawndart]

Re: Chewbacca Build

Nice! A Chewie is on my list to do at some point, keep up the good work.

 

[jweger77]

Re: Chewbacca Build

Arrrrrggghhhh...Chewie says this is gonna be killer when it's done. Did you have any problems with the face casting? I ask, as i've read on other posts about the plaster becoming too warm when it is contact with the skin (i'm thinking of doing myself in Carbonite) and buring your face etc.
Keep up the great work!!

Don't worry about the plaster becoming too warm. When you hear that it's from folks who've tried to make a mold of their face using only plaster. yes, that is a bad idea for sure! When you used alginate with plaster bandages on top of it, there are no issues at all. Check out this if you'd like to do it https://www.youtube.com/user/brickintheyard They have a ton of videos on casting all types of things and have some great informational videos on how to do them.

Thanks all for the positive words!

 

[GenoDesigns]

Re: Chewbacca Build

Hope chewie comes out great! Love seeing the process ....I learn so much! Thanks jweger!

 

[jweger77]

Re: Chewbacca Build

No problem Geno! I hope that this, as so many great threads here are helpful to others! Now that my lifecast armature has been sealed this morning and more plastilina clay has been picked up; it's time to start sculpting the underskull...

 

[jweger77]

Re: Chewbacca Build

https://plus.google.com/photos/112058493433897833379/albums/5601515397783108593?banner=pwa

For anyone working on, thinking about, or just interested in doing a Chewie...the above library of photos is instrumental in helping! Thanks so much to Matt for compiling these!

 

[jweger77]

Re: Chewbacca Build

Sculpting is something I've never done before. Here's the small start from today.

 

[jweger77]

Re: Chewbacca Build

Okay, making some good progress this evening...though I'm done now as I've totally run out of clay. I'm actually having a lot of fun with this part of things. I've spent 3.5 hours so far on things. I had to increase the size of the muzzle because it was too small, otherwise I may have made it a bit further.

Any help or constructive criticism would be greatly appreciated on the sculpt!

 

[jweger77]

Second evening of sculpting and this is the result. I think I'm getting pretty close here. The nostrils are giving me the fits to a degree though. How is it looking?

 

[jweger77]

Took a trip 50 miles each way to Reynold's Advanced Materials to pick up some things needed for the build. Definitely somewhere you walk out of with a lot less cash! Picked up 2 trials of the ecoflex 00-30, pigments for silicone, trial of oomoo 25 for molding parts of the bowcaster, a trial of some faster resin for casting greebles, knobs, etc, some foam it 10 slow for the underskull test and some other assorted junk.

Picked up all of the fiberglassing materials as well. Got them at advanceautoparts and ordered online and saved 20 on 50 purchase. So I'm ready to go!

 

[ultramantaro]

nice work for your first sculpt ! *subscribed*

 

[jweger77]

Thanks ultramantaro! This part has been a lot of fun! That's the best part of doing costuming and props; learning new things!

Here's the update for today...

Okay...cleaned up the sculpt a bit more this morning and it was time to start the fiberglass mold of the sculpt.

Mold wall made of aluminum trim coil. Mold release applied liberally...we'll see how well it comes out tomorrow morning!

Gelcoat made of a 50/50 mix of bondo and polyester resin applied over the entire sculpt to preserve the details a bit more. Worked very well!

First layer of fiberglass going on..

 

[TK9336]

Love it man! I need to come to the armor party your planning and see this in person! And I'll bring my Daft buckets if they arent already at the chromer! Now I can be a hipster and say I knew you before the Chewie! Hah!