My son loves the movie "Castaway" with Tom Hanks. He was devastated by the loss of Wilson in the movie so he wanted to make his own to keep. This was going to be the first time that he dipped his toe into the waters of prop making so I wanted to keep it simple and cost effective. The total cost for this project was about $20.
We got the screen printed version of Wilson on Amazon for about $15 and the rest of the stuff we had around the house.
We started with the ball:

It's not too bad for $15. We scrubbed off the "Castaway" branding logo on the back so it looked a little more screen accurate but other than that, our prep work was done.
Next was the fun part - cutting open the "head".



After creating the top opening, we cut a large hole in the inner rubber air bladder and began the process of weathering. The weathering was a simple brown acrylic wash and some creative trimming.

Unfortunately, I didn't document the process as much as I would have liked, but in the end, we snipped some palm fronds and other stuff from our front yard landscaping and jammed it into Wilson's head. The end result isn't half bad! The whole process only took a couple of hours and my son was very proud of his work.

We got the screen printed version of Wilson on Amazon for about $15 and the rest of the stuff we had around the house.
We started with the ball:

It's not too bad for $15. We scrubbed off the "Castaway" branding logo on the back so it looked a little more screen accurate but other than that, our prep work was done.
Next was the fun part - cutting open the "head".



After creating the top opening, we cut a large hole in the inner rubber air bladder and began the process of weathering. The weathering was a simple brown acrylic wash and some creative trimming.

Unfortunately, I didn't document the process as much as I would have liked, but in the end, we snipped some palm fronds and other stuff from our front yard landscaping and jammed it into Wilson's head. The end result isn't half bad! The whole process only took a couple of hours and my son was very proud of his work.

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