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  1. chefhawk's Avatar
    Member Since
    Aug 2007
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    418
    Sep 21, 2017, 7:57 AM - Chewbacca Mask version 4 New sculpt #1

    I decided that it was time to try and get a better Chewbacca mask made.

    This is going to involve allot of work

    1) Sculpting over a face cast of myself. I use Chauvant nsp clay which is a mix of hard and the medium grade.
    I already had the face cast from previous projects.

    2) casting the sculpt after waxing it to release from the mold. I will use a gelcoat layer made from resin and bondo. It will be then reinforced with fiberglass and resin.

    3) Once cured, remove the clay and face cast from the from the mold

    4) Roto cast with plastsil gel 10

    5) Remove silicone appliance and then wax interior of the fiberglass shell/mold then spray layers of p.v.a to form a release plastic layer, a bit like sprayable shrink-wrap or cling film in the uk.

    6) lay up fibreglass

    7) Remove this for using as an underskull

    8) cut out eye sections and jaw in the underskull

    9) Sculpt and cast teeth to fit jawline of the underskull

    10) sculpt inner mouth. Bottom pallet and tongue with upper pallet - cast this in hydrostone to make a bold. Use platsil gel 10 to pour into gold to make the appliance

    11) Paint resin teeth, paint the tongue, paint the nose and lips after cutting out the eyes, lips and nose.

    12)Hinge the underskull, make lip mechs for the upper lip

    13) Add negative industrial velcro to the underskull add positive velcro to the silicone

    14) Finish adding the mech to the underskull, add the appliance back, attach the mechs.

    15) Add netting to top and back of the mask, Latch hook mix of hair from dark grey to light grey. Latch hook blond to the sides.

    16) Lay up the blond hair onto the face and sides of the face.

    17) Hair punch the chin area with blond hair, hair punch the grey moustache.

    18) Thin out hair with thinning shears, style the hair and touch ups.

    Heres a video of the sculpt.

  2. RPF Premium Member elilay's Avatar
    Member Since
    Sep 2015
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    217
    Sep 23, 2017, 12:19 PM - Re: Chewbacca Mask version 4 New sculpt #2

    Most impressive ! Will you make video during hair work?
  3. chefhawk's Avatar
    Member Since
    Aug 2007
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    418
    Sep 24, 2017, 11:53 AM - Re: Chewbacca Mask version 4 New sculpt #3

    Unfortunately I won't be doing a video at this time of the hair work...

    sorry
  4. RPF Premium Member DaddyfromNaboo's Avatar
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    Mar 2004
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    Germany
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    Sep 24, 2017, 1:29 PM - Re: Chewbacca Mask version 4 New sculpt #4

    See you in that costume at CE IV !
  5. CatfoodRob's Avatar
    Member Since
    Jan 2009
    From
    Warrington U.K.
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    318
    Sep 27, 2017, 1:00 PM - Re: Chewbacca Mask version 4 New sculpt #5

    DaddyfromNaboo said: View Post
    See you in that costume at CE IV !
    If you have any inside information on when that might be, we'd all love to know !!!!!

    Chef..looking forward to seeing this in the flesh soon enough !
  6. chefhawk's Avatar
    Member Since
    Aug 2007
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    418
    Sep 29, 2017, 3:38 PM - Re: Chewbacca Mask version 4 New sculpt #6

    Here is a tutorial video part one of the mask.

    I had deadline to entertain kids at a disabled school and a sci fi weekender to get this finished.

  7. RPF Premium Member DaddyfromNaboo's Avatar
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    Mar 2004
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    Germany
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    Sep 30, 2017, 8:48 AM - Re: Chewbacca Mask version 4 New sculpt #7

    Fantastic!
  8. chefhawk's Avatar
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    Aug 2007
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    Oct 14, 2017, 8:22 PM - Re: Chewbacca Mask version 4 New sculpt #8

    Last edited by chefhawk; Oct 20, 2017 at 9:23 AM.
  9. chefhawk's Avatar
    Member Since
    Aug 2007
    Messages
    418
    Oct 18, 2017, 10:58 AM - Re: Chewbacca Mask version 4 New sculpt #9

    Here are some photos from a troop with the Britannia patrol form Saturday with the new V4 mask




  10. chefhawk's Avatar
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    Feb 5, 2018, 2:21 PM - Re: Chewbacca Mask version 4 New sculpt #10

  11. chefhawk's Avatar
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    Aug 2007
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    Feb 21, 2018, 12:09 PM - Re: Chewbacca Mask version 4 New sculpt #11

  12. chefhawk's Avatar
    Member Since
    Aug 2007
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    418
    Apr 16, 2018, 9:01 AM - Re: Chewbacca Mask version 4 New sculpt #12

    Rarely do I get A chance to film someone else with the new mask on...

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