Help & Guidance Needed: Jar Jar Binks Mask Project

[jediwilliam]

Hi everyone,

I'm a long-time admirer of the amazing work on this forum, and I'm hoping to tap into the community's collective wisdom for a project that I'm incredibly passionate about, but have hit a major roadblock on. My goal is to create a high-quality, wearable silicone mask of Jar Jar Binks with a functional, moving jaw. My starting point and primary reference is this beautiful, life-sized bust that I've acquired.

My Journey So Far:I've spent a significant amount of time and resources trying to tackle this on my own. I've learned a lot from my "failures," including that simpler methods like plaster bandage molds or single-piece paper mâché shells are not suitable for a complex shape with so many undercuts (especially the eyestalks). I'm now committed to doing this the "right way" to honor the project and get a result I can be proud of.

Where I'm Stuck:I've done enough research to know that the next logical step is to create a multi-part, brush-on silicone mold with a rigid mother mold (like Plasti-Paste). Frankly, as a solo operator in a rural area (Pendleton, Oregon), the scale and technical precision of this step are intimidating, and it's the critical point where this project will either succeed or fail.

How You Can Help / The Ask:This is why I'm reaching out. I'm trying to figure out the best path forward and I'm open to several kinds of help:

1. Advice & Resources: Are there any specific tutorials, build threads, or materials you would highly recommend for an ambitious creature mask like this? Any "I wish I'd known this before I started" tips would be invaluable.
2. Mentorship/Guidance: Is there anyone in the Pacific Northwest (Oregon, Washington, Idaho) with extensive experience in silicone mold-making who might be willing to act as a mentor I could bounce ideas off of?
3. Commissioning Help: I am seriously considering hiring an experienced artist or prop maker to handle the most technical phase of this project: the creation of the mold itself. If this is a service you offer, or you know a trusted artist who does, I would be very interested in discussing a potential commission.

I'm really passionate about seeing this through and doing it justice. Thanks so much for taking the time to read this, and for any guidance you can offer.

Best,

 

[JPH]

Use Dragonskin 10 for the brush on.
Apply first layer to avoid bubbles. It will capture details.

Dragonskin is very stretchy, thats why I used it for valves on my Kosh cosplay. Itwill strech past wide and small areas, but always apply release agent.

Make LOTS of registration points. In other words, after applying 3 or 4 layers of dragonskin, get some foam and embed little 1cm pieces of foam in the dragonskin.
When you make a hard outer shell, the registration points will help assure the mold holds its shape. I use Freeform Air for the hard outer shell. Make the she in a couple of pieces. Apply aluminum foil where two seperate pieces meet. You need to use bolts of rubber bands to hold the different pieces of out shell together.

Do the ears separate from the head and eyes.

I would slush cast the head in Task 16 rubber. Pour 4 oz of it, then dance around with it to make a thin layer. Repeat, holding your mold up to a light to see when the slush cast layer blocks light...thennit is thick enough

Make a skeleton that starts with a baseball cap on your head. Add straps under your chin then use FreeForm air to make a sculpt a helmet that perfectly fits your head. Anchor a skeleton to this.

Depending on how articulated, maybe an aluminum frame or even consider molding a silocone internal frame with memory that will return the head to midline.

Id make the mandible and maxilla out of aluminum. Drill holes in it forweight and it you add silicon of rubber to get them to hold shape.Make sure it is sanded smooth so no sharp edges cut through the Task 16 skin.

 

[jediwilliam]

Wow, thank you so much for this incredibly detailed and generous response. To be honest, I'm in a pretty remote area and was feeling completely overwhelmed and on the verge of giving up on this project after a few failed attempts. Your post felt like a complete, professional roadmap and has given me a renewed sense of hope and a clear direction.
The advice to make the ears modular is brilliant, and the breakdown of how to build the internal helmet and jaw skeleton finally made the whole "moving jaw" part click for me. It's practical, expert advice like that (and the foam for registration points!) that I could never have figured out on my own.
I'm putting together my shopping list now based on your recommendations. Thanks to you, I feel like I'm finally on the right path. I'll be sure to start a proper build thread here to document my progress.
Seriously, thank you again. It's expertise and generosity like yours that makes this community so amazing.
> All the best,