This is an epic build, looking forward to watching your progress. Do you use any particular clay for your sculpted parts and for your purposes does it work as well or better than something like apoxie sculpt? (I'm new to sculpting, just ordered some apoxie earlier this week.)
Thanks for sharing the details along the way, good luck moving forward!
Thanks bud. I use various materials. I really like monster clay for technical sculpts that I plan on making reproductions of and I use Sculptex medium for quick and dirty sculpts (I used klean Klay for my ELite sculpt which is Sculptex now - link is in my signature). I also use "free form earth" ( i think it has a new name now) for one off epoxy based clay sculpts, stuf I don't plan on making duplicates of(same as the apoxie sculpt you mentioned, its just cheaper), I like epoxy based clays for shaping existing hard models, like 3d prints or Hardened pepakura models, of scratch built items.
I know it's been said before, but this looks epic. Such a clean build and the castings look great. Good to see other warlocks out there
Thank you my friend, I look forard to joining the ranks of my fellow warlocks out there.

You doing Dragon con this year? If so, I'll be there.
Great build.
I wanted to ask, what did you use for the mother mould? Was it Plasti-Paste?
If so, how much di you use, roughly, was it a few starter sets or a gallon tub?
Many thanks, after my coat sewing session, its silicone onto the helmet buck here, so getting all the last bits ready
Thank you so much for the awesome comments and feedback. It means a lot. For the shell/jacket, I use a material called "free form air" it's an epoxy dough, takes a little while to fully cure but it's the easiest stuff I've ever used to create a support shell. started using it with the Elite head sculpt and have never gone back to any other material. It took roughly a full gallon to do the whole helmet. THis does not include the Jaw piece (in the pictures below). I think a whole gallon would work though. I went a little heavy handed with it

. I'll be using fiberglass on the jaw mold below tonight.
Wow! That looks like a great approach to doing the mold. Seems like most people opt for a single piece helmet mold, but it looks like your method will work out nicely.
Thank you! Yes, I planned on having the helmet be multiple parts so it could fit the head more form fitting like the in game helmets. To do this, meant more molds

I think it will look good and have less of a bobble head apearance. It has been a lot more molding effort though. I think it will pay off in the end. Fingers crossed.
Here is where I am as of today on the Helmet mold. Sorry it's taking so long, I have to fit it around juggling life and such. I also play Destiny a crap load....lol
Prepping for rubber (takes a while):
First layers (no thickening):
Second Layer (Thickened):
Third Layer (no thickening & prepping for mold jacket):
And.......work on my girlfriends Hunter stuff (i may redo the horn thingy):
"Don't touch me" gauntlets
Thanks again for viewing everyone!
-Tony