Sauron helmet

[BlindSquirrel]

Waaaay back in '04, I built a Sauron costume for Halloween. As you can see here, I was going for approximate looks. Fortunately, it was good enough to win some prize money and I put that into the UC Sauron helmet.

After staring at this pre-RPF costume for the past 3 years, I've decided to start "accurizing" the suit, starting with the weakest link, the helmet. Any one who has the UC helmet will attest that this thing is HUGE. I'm 6' tall and I look like a bobble-head in it. I did some calculations and it looks to be 15% too big (for me).

Here I'm about 20 hours into my first clay sculpted piece. I'm working on the full-head cast I made of myself last Christmas so I know the final piece will fit.

Of course this could all be for naught, as making a mold of this thing will be a real challenge. I'm thinking that I should sculpt it without "horns", make a brushed on glove mold with a multi-part plaster, mother mold and then slush cast the helmet out of resin or fiberglass. Then sculpt the horns and cast them individually. Sound like a plan? Any suggestions?

 

[Hecubus114]

All I got to say is great start!

 

[Soundwave]

Looking great so far!! Can't wait to see the progress of this and it can only make a great costume better!

I think casting the horns individually and your suggestion is a good idea.

 

[darthvaderv]

It's looking really good, nice work :thumbsup

 

[Petseal]

I have to agree, it looks awesome so far!
But I have a question that you may be able to answer!
Are you making a helmet or a helm and does anyone know what the difference is?
The only thing I know for sure is that helmets usually only cover the top and, at most, three sides of the head! Like most modern military helmets!
Just something to think about as you spend hours carving your...?
Later, Petseal

 

[BlindSquirrel]

Well, I believe that the sculpting for Sauron's noggin is DONE. Next I'll need to pick up some brushable rubber to make a mold. After I get the resin casting I'll sculpt the "horns" so they can be cast separately. Lucky for me that my first sculpt has rough detail. I can see how difficult it would be to get something tech smooth!

I just saw the Sauron bust in a store and noticed that there's much more detail in the runes than on my UC full size helmet. I guess I'm going to have to figure out which direction I want to take this...I think it can easily be added to the casting later.

As for "Helm" vs "Helmet", I dunno. I always thought that helm was an archaic version of helmet. Might have to research that one.

 

[Too Much Garlic]

I like how this is shaping up. Keep up the good work and progress shots! :thumbsup

 

[jedimarkj]

Excellent progress! I can't wait to see it completed!

 

[Soundwave]

Yeaah liking the progress so far, the details are great!!

 

[Forsaken]

Looks great BlindSquirrel.

Now all you have to do is build a mile high tower to reside in.

Al

 

[godaiking]

Looks bad ass. Awesome work!

 

[BlindSquirrel]

I finally demolded my resin helmet...

...when I made a horrifying discovery.

The local toy store got in one of Sideshow Collectibles Epic Scale busts of Sauron. The detail and edges are MUCH cleaner and defined than the United Cutlery Helmet that I own! I was surprised at the rough, organic feel of the UC piece when I got it but I figured that since it was "official", it must be right. The bust looks much more accurate and at least captures the feel of what I saw on screen.

I suspect I can still salvage what I've done by some creative sanding..

and adding the ornate scrollwork afterwards.

Anyone own this bust that could help a brutha out with some reference photos?

 

[Kylash]

man thats crazy, it looks just like you shrunk down the UC helmet. Ive had mine for years and that helmet is just identical..

 

[BlindSquirrel]

man thats crazy, it looks just like you shrunk down the UC helmet. Ive had mine for years and that helmet is just identical..

Thank you. It is EXACTLY 15% smaller than the UC or should I say the UC is to big (for me). I'm 6' tall and I look like a bobblehead in the UC...not to mention it's crazy heavy.

 

[PTK]

beautiful work! i can't wait to see it done

 

[Aluke123]

Dude, that thing is sick. I wish I had a costume that good...

Keep up the progress shots!

 

[Guri]

Awesome.

Have you thought about casting it in pieces and then putting it together after? Not sure this would help, but this is how I broke mine apart to give you an idea of what I mean:

I imagine something similar could be done and then some sort of adhesive used to put it back together... (mines craft foam, so velcro works fine for it)

When I built mine (ridiculously inaccurate, but fun none-the less) I went off of photos of the UC and whatever screen snaps I could get. I had no idea either that there was so much sharp scrolling.

I'll be keeping my eye on this thread - keep the in progress photos coming!

 

[BlindSquirrel]

Here's the recent progress shots of the helmet. I still have to do the back spike but the others are done.

I started to do the scrollwork detail...I carved this from Aves but it took bloody FOREVER! After it dried, I sanded it flat (not shown) and it looks nice and crisp!

On my old costume, I used puffy paint for this detail but it's not crisp enough (and it can't be sanded). Any suggestions for an easier method for raised scrollwork?

 

[Hecubus114]

I saw a method once but dont remember all the details... but it basically was just using a stencil and brushing on a thick material, then lifting the stencil... if I remember/find more than that I will let you know...

 

[Ramiel]

Holy cow in a jelly! :eek
I want one!

For the raised details you could use the stencil method mentioned by Hecubus, or you could experiment with (and this is a "last minute idea", so I've just invented it) cardboard/cardstock soaked in resin, previously "chieseled" into a desired pattern... I have no idea if this could work, so I don't take responsibilities for any damage!

Keep posting!
And let us know if you will making copies!