The Simpsons - Krustyland Theme Park Hat

[agliarept]

Visited Universal last week for Halloween Horror Nights and was let down by the lack of fun merch for Krustyland. I figured, if the mouse can have hats with ears on it, so could Krusty.

my thoughts were then validated when I saw the below Bart plush wearing one! So, I decided to tackle this project as a challenge in both 3d sculpting and manufacturing, as I've never produced a hat before.

Here's the photo i'm referencing for inspiration:

What I'm basing my sculpt for the hair on:

What i'm basing my colors on (since Krusty has very varying colors used throughout the show:

My sculpt so far (it's been updated since this photo and prepped for 3d printing on Monday 10/23).

Base Hat (this is a happy medium i'm comfortable with for both the off-white/cream and the pink/orange/sometimes brown mouth color lol)

Here's a VERY CRUDE mocked up with the eyes/nose patch I designed ( i think each hair piece will be 7" in length)

I'll circle back once I have some in-hand tangible parts to mock up and refine.

Aiming to have this done by November.

 

[agliarept]

After several failed prints (too oversized, ill supported, bad orientation) I now have my prototype pieces ready for paint and attaching.

The pieces are hollow and only 1.3mm thick, so light.

Need to figure out what glue would work best with resin and fabric. Any recs?

 

[MattgomeryBurns]

Would strong magnets work too?

 

[agliarept]

Would strong magnets work too?

That was my initial thought, but I want this to be used at the actual park and sustain mild abuse while walking around.

I opted for e6000 epoxy and currently spray painting the parts, so they're ready for assembly tomorrow.

 

[agliarept]

resin parts painted, ready for mounting. Went with "Spring Green" which i thought was a nice color and nod to Springfield.

Here's the first set painted and waiting for mounting.

 

[probablyjarrett]

 

[agliarept]

Very happy with how it's turning out so far, only missing the eye/nose patch getting made

Here's an assembled mock up. Hat's very lightweight and not obtrusive to wear.

 

[scarf man]

Very nice, now cease and desist using my client‘s image and likeness.

… you know what, my client endorses too many products for me to be sure you are not sub-contracted slave labor, carry on.

 

[agliarept]

LOL!

Ordering patches today to make a limited number of these eventually.

Was given some good advice on maybe casting the ears in self skinning foam? Would make more sense but have to figure that out downstream.

 

[agliarept]

It's finally done and I love how it turned out. Gonna wear it to the park sometime next month.

Have enough parts to make 22 of these so will put up an interest thread to see if anyone wants one.