Foam Sculpting My First Bio - Beyond The Final Rung

[BonzRus]

A truly amazballs way of making a bio dude, superb. Can't wait to this cast. And the inside is the mutz nutz.

Thanks, I appreciate it.
 
 

So pretty! Does this mean we're gonna see the first pull in a week or so?

Brian

Well, If I can get the inside part of the mold made then yes. I am getting ready to make the mother mold as I type this so I should get started on the inside next week.
 
 

Looking good bud, about time that went under the silicone lol clearly you teleported back and got it lol

Hey Jason...it's been awhile. Where you been hiding? I got it back while you were at NEC...Ha!
 
 

It's been a while since I've stepped in to see your progress and all I can say is, WOW! This thing is so gorgeous and detailed!

Thank you very much! I am excited to be at the molding stage.

I will update more on Monday when I can post more pics.

Steve

 

[BonzRus]

OK. Over the weekend I was able to fill in the undercuts with silicone, cut my registration keys, build the plastic flange out and make the fiberglass mother mold front half. There are a few minor things I need to correct with the silicone but overall it turned out very well I think for my first attempt at this. It had been awhile since I actually saw the inside of the helmet... good to see it again. The important thing is that in the process I learned some things along the way. One of the main things is that I need to use resin Jelly to fill in the areas around the registration keys and along the flange prior to laying the fiberglass mat. I thought I could make it work without it and ended up having to fill in some air pockets in the fiberglass after the fact. Here are some more pics.

Undercuts filled in, registration keys cut, plastic flange built up where needed and ready for the fiberglass mother mold to be added. I applied 5 coats of Caranuba paste wax to the plastic flange and then sprayed the whole thing with Mann Ease Release 200.

Building up the fiberglass shell...

Trimmed the edge with a Dremel cut-off disc and gave it a quick coat of primer...then breaking away the plastic flange.

The flange removed...

The clay removed...

The lenses removed...

A close up of the flange with the resin Jelly added...

I need to clean up the flange, clean the clay residue from the silicone and correct a few issues with the silicone but this is basically where it is at, ready to start building up silicone on the inside.

I know this is a big update but there was a lot that went on in a relatively short amount of time. I am excited about the progress so far and anxious to get the inside done. I may need to order some more silicone to complete the inside which could push out a first pull an additional week or so. If it does then oh well...I am not going to short-gut this. I also need to order some plastic funnels for pouring the resin when it is time and oh by the way, I got the laser diodes I ordered. YAY!!!

That's all for now,

Steve

 

[PredatrHuntr]

That looks cool!  Great job on the silicone/mother mold process - this is a huge update and I'm excited for the next process

 

[BonzRus]

Thanks Jason! Yes, this could be my one giant leap update.... Tonight I will work on cleaning up the flange and repairing the silicone places that need it. I hope to start applying silicone to the inside on Tuesday. The missing piece of this is that I still have not been ale to get a look at the inside of the silicone to see how it turned out and wont be able to until the inside is completely done and then I can take it all apart. Oh well...I've waited 5 months to get to this point, what is another week or two?

Steve

 

[AlphaTech686]

Hey Dude, this is very clean and professional looking. Very nice work. Keep the updates coming.

 

[AlphaTech686]

Hey Steve I just put this on the spear post but I will say it here as well. I can whip up a mold but they sure aren't as pretty as yours.

 

[BonzRus]

Jeff, I am humbled...Your spear build as with everything else you make is phenomenal to say the least. I know it is taking you a long time to put it all together but I dare say it rivals even the movie made suits. Thanks for all your help by the way. I greatly appreciate it.

Steve

 

[wonko]

I can't believe how clean your mold turned out Steve...blows my mind.  I'm anxious to see how the inside comes together, and how you pour the resin when it's ready.  Thanks for the update!

Brian

 

[Okami Skullcrusher]

Mold made on laboratory conditions?! Amazing clean work!

 

[BonzRus]

Mold made on laboratory conditions?! Amazing clean work!

Not unless my dusty dirty work bench can somehow be classified a lab environment...don't be fooled by the pictures. I have to spend a lot of time cleaning all the sanding dust off of everything because I make so much of it. 

 

[BonzRus]

Here are some before and after shots of what I did to fix the blemishes in the silicone. I basically just took Clay's tip about using the plastic wrap and covered the places where I applied the silicone to smooth it out...looks like it worked great. Thanks for the tip Clay!

Before...

During...

After...

You get the idea.

This is the finished front half of the mold ready to start applying the silicone to the inside.

Looks like I have enough silicone to come close to what I need but I am going to need another gallon to probably finish this and get the detail pieces molded up...plus have a little left over to make a mold for my dreads.

L8r,

Steve

 

[Eaglewood]

glad to help--looks great

 

[REYALS1]

What we are seeing here, is the work of a mad man.

This has got to be the cleanest, most professional looking mold on the Lair. I'm simply blown away by the beauty of it. I mean...WOW!

 

[BonzRus]

glad to help--looks great

Thank you Clay.

What we are seeing here, is the work of a mad man.

This has got to be the cleanest, most professional looking mold on the Lair. I'm simply blown away by the beauty of it. I mean...WOW!

I am the one who should be saying WOW! Thank you for the kind words Ricky.

 

[BonzRus]

First coat of silicone went on the inside last night. Will apply a thickened coat later today. I have become much more relaxed with how to use this stuff.

Steve

 

[oxtheii]

It is really coming along nicely and is so professional looking, keep it up!!

 

[BonzRus]

It is really coming along nicely and is so professional looking, keep it up!!

Thank you Oxtheii. I am trying.


Just a quick minor update. I got one thickened coat of silicone applied last night and now I am out of silicone. It didn't go as far as I thought it would... Oh well, I will take the down time while I am waiting for more to come in to prepare the molds for the detail pieces. Gotta' keep pressing forward.

It's not much but here is the latest progress pic.

I will update on the detail pieces as I go.

Steve

 

[PredatrHuntr]

That is turning into a seriously wicked looking mold!  Thanks for all the update pics - this is fun to watch

 

[xdmray]

may i ask why you are making a two part mold since there is no detail on the inside of the bio?  and after you have made the back half, what is the plan for casting?   you are the first person i have seen do this and i was wondering  the plan.

SUper huge kudos on one of the cleanest looking molds ever.  you did an amazing job on that.   in fact this whole process you have done has been top notch.

 

[wonko]

If you read back in the thread a little ways you'll see that the best part of this bio is the finished interior details.

Brian