Just wanted to give a small update (no new pics, sorry).
We have done 4 test pulls so far, testing both the type and amount of urethane. It is a real challenge because soft urethane begins to expand in less than a minute and because of the length of the ears and the overall complexity of the face, it is a bit of a challenge to make sure it gets into every section and that we can get the two halves together before it begins to set.
So far, we have been doing the paint in the mold and testing different colors to do it. The colors are coming out really well, but just missing that certain something that they need to be as close to screen accurate as possible. We are taking the last two pulls, one that was prepainted in the mold and one that was not, and having Tom Spina Designs do the final touchup to the paint in the eyes, teeth, inner mouth and inner ears.
Tom is also prototyping up the hood for me and that is going to be interesting as it seems like a very simple and straightforward piece, but it actually has a slight bit of complexity to it. We also are going to have the opportunity to match our fur to some original fur from one of the screen used pieces! Don't know whether that is just going to depress me (because we are so far off) or thrill me (because we are so close), but we will see.
While Tom is working on this for me, I am having one more test run with a more dense urethane. Because all of the original masks are now hard as a rock, there is really no way to know what their density was, but I feel like we need to go just a bit more dense with the foam for these... just to give them a little more heft, stability and structure. The challenge there is that denser urethane doesn't expand as much which means we need to make sure we get enough of it in the mold. The other concern is that since it doesn't expand as much, we have to make darn sure we get enough into every crevice, especially down into the teeth and into the ear folds.
Not holding my breath, but hopefully in the next two weeks we will have a new, more dense test pull (a final test pull), two paint masters, and at the very least, a prototype hood.
A lot of people have asked if I will make these available. This is not an interest or sales thread and I am not interested in drumming up sales here, but so people don't think I am ignoring them, yes, I plan to offer a very small run of these as collector items. I doubt I will post anything publicly in the Junkyard, but you will know it is ready when you see finished photos here.