My death eater mask

stormtrooperguy

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RPF PREMIUM MEMBER
It's been a long time since I posted any projects here, so I figured I was about due.

I'll say right off that this was not about 100% accuracy. I gave myself a fixed timeline for the project as an exercise, and got it as accurate as I could in that time.

With the disclaimer out of the way...

I wanted to make a Death Eater costume to wear to the final Harry Potter movie. This seemed like a great time to play around with a face cast as well.

This is the mask I decided to go with:



I had a friend come over to do the cast. Neither of us had done it before, so things didn't go fantastically. We learned the value of not putting straws in the person's nose. One of them got driven up into my nose, resulting in a LOT of bleeding. Ah well, suffer for my art! We also used about 3x as much alginate as was needed...



Despite all that, the cast came out serviceable:



I cleaned up the defects then started packing on clay. I was using Chavant Le Beau Touche HM for the sculpt.





For the "teeth" I made a stamp so that they would all be uniform. Just a piece of 1/8" thick styrene cut to shape and pressed in. They'll be cut out of the final mask, so they only need to give me the appropriate guides.



More lines carved in:



The colder the clay is, the firmer. So, I stored it in the freezer when not actively working on it.



Fast forward through several nights of carving lines and smoothing clay.

I didn't take pictures of me brushing silicone onto it. That's not very interesting.

I used leftover plaster bandages from the head cast to make the support shell, and built in little bumps so that it would stay level on the table when I was casting it.



The mold captured the details of the carvings well:



First casting:



I painted up 2 of them. One was a quick prototype that I painted with a matte silver paint and did a bit of black acrylic detailing on. This was just to make sure that I'd like the look.

The second was finished with rub & buff and a more detailed paint job with a copper color around the eyes and some weathering.



I still have to cut out the teeth so that I can breathe and talk.

I've got the outer robe and wand done too, but don't really have any pics yet.
 
OMG! That is *** beautiful. Very well made and professionally done. Love it!:thumbsup
 
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Out of interest (and I may have missed this bit, so apologies if I have)... what's the finished mask made out of? It looks like there's fibreglass in that 2nd from bottom pic, but I wasn't sure if it was a complete fibreglass build, or whether that's just your reinforcement I can see?

When you drill the teeth out, are you going to put something behind them to keep it blacked out? If so, what are you thinking of using? (mesh with fabric overlay maybe?)

I love the weathering on it. I'm really tempted to have a go at one of these now as I've been looking for another little project that won't break the bank lol

Hat's of to you - that's definately one of the nicest, most effective mask builds I've seen. sincerely well done!
 
The mask is made from Smoothcast 65D, a casting resin from Smooth-on. The bits you see sticking off aren't fiberglass... they are just the excess resin around the edges.

I usually use black nylon to fill in air openings, stolen from my wife's stockings that have gotten runs in them and are headed to the trash :)
 
this looks great!!! i am working on my death eater costume..however, because of expenses...i'll be using paper mache lol
 
Looks great! 65D was a great choice for your mask too. It's semi-rigid properties make it a lot more impact-resistant than the other rigid resins.
 
Looks great! 65D was a great choice for your mask too. It's semi-rigid properties make it a lot more impact-resistant than the other rigid resins.

thanks! i use a lot of the 65d, even for solid castings. that semi-rigidity has saved me from many a repair :)

speaking of... i've got to get out to the local reynolds am store and pick up another 5 gallon bucket of it this week!
 
Does the inside of the mask conform to your face? Also are there two halves to the mold? how did you make the mask so thin?
 
It's a 1 part mold. The resin is painted in, so it only builds up a thin layer. I'd say it's about 3/32" thick or so overall with some parts as thick as 1/8".

The 65D resin gels up gradually... it's designed for rotational casting, so it works well for this sort of thing.

It conforms to my face pretty well, but I did build up quite a bit of thickness in clay over my face cast, so it's not oppressively tight.
 
Really like how that finished up, looks wonderful.

As a clarification (noob!) the process was create face mold > cast clay > take another face mold with detail > cast resin? I think thats right but not sure?
 
Yup, that's it.

Alginate mold of my face, resin cast from that mold (should have been plaster, but I didn't have any at the time!). Clay sculpt on the face cast, silicone mold of that sculpt, resin cast of the final mask.
 
Those look great! The scrollwork on the face had to be hard to get that symmetrical. Definitely digging the weathered version.
 
sorry if this is being cheeky but how did this cost you like materials wise etc. Im working on a mask from pep>resin>bondo so on, still to finish details then making a mold for it. Can you get 65D in the UK?
 
doug - I hadn't really thought about it, but I suppose I could make a few up and post 'em in the junkyard.

digger - I probably spent about $60 - $75 on the mold, and $20ish on the casting.
 
OMG is that blood on the lifecast, that's freakn hilarious! I have to be honest though, I cut the crap out of myself several times and poisoned myself with paint and epoxy fumes "enjoying this hobbie" :lol Very nice work the mask looks great!(y)thumbsup
 
OMG is that blood on the lifecast, that's freakn hilarious! I have to be honest though, I cut the crap out of myself several times and poisoned myself with paint and epoxy fumes "enjoying this hobbie" :lol Very nice work the mask looks great!(y)thumbsup

Yeah... so the whole straws up the nose thing didn't go well! The person molding me whacked one of them up into lobotomy territory. Blood started pouring out like a fountain!

It all cleaned up just fine... nothing a bit of hot water and bleach can't remove. But the photo that way was so much more dramatic :)
 
Brian,

Yours turned out great, I really like the look of it. I forgot to tell you how much I liked the other one you sent down my way. I still need to put some weathering on it, but it turned out sharp.
 
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