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Oregon Tarfful Build
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Beckett ()
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Joined: 22 Oct 2015
Posts: 156
Location: Oregon, USA
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PostPosted: Mon Jun 11, 2018 2:19 am    Post subject: Chewie and Tarfful together Reply with quote

Worked on his nose more today. feels like its getting closer to a finished sculpt. got to a stopping point with both sculpts we have going and took a photo.
[img]Untitled by Josh Beckett, on Flickr[/img]
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Beckett ()
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Joined: 22 Oct 2015
Posts: 156
Location: Oregon, USA
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PostPosted: Wed Jun 20, 2018 1:21 am    Post subject: Tarfful sculpt Reply with quote

So, after letting the Tarfful sculpt sit for a week or so and just focussing on the Chewbacca sculpt I was able to get a set of fresh eyes on it today andmy brother and I sat down and thinned the high cheek bones a bit and then rounded then feeling like they weren't quite accurate. After the slight changes to the Tarfful we set our sights on starting the mother mold. So we laid him flat and secured him with clay then built up a clay wall around him then used some simple painters tape to build a wall up in case the material we are using (Epoxicoat Red) started to drip off the edges.

Here's a photo of Tarfful all set up and sprayed with release:
[img]Tarfful and Chewie progress by Josh Beckett, on Flickr

after the first coat of Epoxy Resin (I don't know why but I really like using this stuff):
[/img]Tarfful and Chewie progress by Josh Beckett, on Flickr

we going to do the second coat here in about 15 minutes and then we'll see if a 3rd coat is needs. We're trying to get the mold about 1/8" thickness.

...and after the second coat. next will hit the eyes, nose, mouth and border with some free form air and overlay the whole thing with fiberglass.

[img]Untitled by Josh Beckett, on Flickr[/img]

got the FFA on this morning. First time working with it and I'd say its pretty interesting. We mostly just used it to further support the lip of the mold and to pack in the face so that when we lay the fiberglass over its somewhat symmetrical.


[img]Untitled by Josh Beckett, on Flickr
[/img]Untitled by Josh Beckett, on Flickr
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Beckett ()
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Joined: 22 Oct 2015
Posts: 156
Location: Oregon, USA
Medals: None

PostPosted: Sat Jun 23, 2018 10:14 pm    Post subject: Update on the mold Reply with quote

Got the fiberglass over the FFA and spent some time cleaning it up. Then we broke down the clay walls and started our mold of the back half of the helmet dome. Since we started the mold process with Epoxacoat Red I wasn't completely sure how mold release does in keeping the Epoxy Resins from bonding to one another so I put a coat of Sonite Wax release and them liberally sprayed mold release before we layed down the Red on the back half. Crossing our fingers that it will release cleanly otherwise its going to be near impossible to get the sculpt and lifecaste out of this thing. Again, we are first timers sort of. Anyway, same process on the back skull, we'll lay the FFA down and then fiberglass it later tonight I think.

[img]Untitled by Josh Beckett, on Flickr

and photo of the work space
[/img]Untitled by Josh Beckett, on Flickr
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Beckett ()
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Location: Oregon, USA
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PostPosted: Mon Jun 25, 2018 1:19 am    Post subject: Digging out the sculpt Reply with quote

Finished up the mold last night. Woke up today and layed it all out in the sun to let the still tacky fiberglass resin harden a bit more. About noon we started trying to pull the sculpt from the mold. Not having done this kind of mold before we were blindly hoping to get our sculpt back, LOL.

This thing was really locked in so we had to start digging it out.
[img]Untitled by Josh Beckett, on Flickr

After LOTS of wrenching on it and digging and heating it and then repeating that process about 20 times we finally started to see some movement. Then the lifecast broke when I pulled on it too hard.

[/img]Untitled by Josh Beckett, on Flickr

and at about 6:00 we finally broke it free. It's safe to say that we lost the sculpt I think, lol.
[img]Untitled by Josh Beckett, on Flickr

The good news was that we have an awesome mothermold that is seriously strong.
[/img]Untitled by Josh Beckett, on Flickr

It's kind of a 1.5 part mold I guess (not sure what the experts call these but we molded the back skull to be able to avoid messing with converting baseball helmets and have the full coverage with the fiberglass underskull. Next we'll line the mothermold with about a 1/4" of clay and create a plug that will be used to create a void where the dragon skin/Ecoflex faceskin will be poured and molded.

[img]Untitled by Josh Beckett, on Flickr[/img]
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Beckett ()
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Joined: 22 Oct 2015
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Location: Oregon, USA
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PostPosted: Tue Jun 26, 2018 7:54 am    Post subject: Plug Reply with quote

Started working on making the plug today. lined the inside of the mold with 1/4" of clay, then sprayed with release and sonite wax and covered with Epoxacoat Red. then we'll line with FFA and top it off with some Fiberglass cover. After that we are ready to make a Tarfful mask.

lined with clay
[/img]Untitled by Josh Beckett, on Flickr

then the RED and then the FFA. The whole time I'm doing this I'm thinking, "man, I sure hope the release works or I am literally starting from square one."
[img]Untitled by Josh Beckett, on Flickr[/img]
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Beckett ()
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Joined: 22 Oct 2015
Posts: 156
Location: Oregon, USA
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PostPosted: Wed Jun 27, 2018 3:52 am    Post subject: Dreads Reply with quote

My wife watched a few Youtube videos today and then did a test run of a dread. This being our first attempt at it we expected it to not look great, which it doesnt but I had a few extra black Jumbo Braids that I dont have a use for so I thought we could just use them as testers. We have two more that wont get used so we are going to put them together and see if we can make one thats more uniformed and thicker.

[img]Untitled by Josh Beckett, on Flickr[/img]
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Beckett ()
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Joined: 22 Oct 2015
Posts: 156
Location: Oregon, USA
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PostPosted: Wed Jun 27, 2018 7:29 am    Post subject: Plug Reply with quote

Pulled the plug from the mothermold tonight. Man! that was rough....several spots on the rim of the plug cracked trying to get it out. I guess we didnt reinforce the rim enough so lesson learned and when we mold Chewie next week we'll make sure not to make that mistake. We were able to salvage the mold and all the registry points though and we went back tonight put some more resin on top of the fiberglass and we're probably going to plasti paste or fiberglass again on top of that to make sure the plug is durable.

outside of the plug you can see one large crack that my thumbs is almost touching. We re-resinned the whole outside tonight and will hit it with more resin and fiberglass tomorrow probably.
[img]Untitled by Josh Beckett, on Flickr

the underside of the plug (face). We did some smoothing with the sanding wheel where the resin seeped into a few cracks that were in the clay. it might get a bit more smoothing before we finally put the dragonskin/ecoflex in but we wanted to add the reinforcment first. Some of the resin wall on the plug was thinner than I thought it was.

[/img]Untitled by Josh Beckett, on Flickr

Another shot of the face of the plug. the lighter areas are from the sanding/smoothing out some sharp edges. Ultimately, they just shape the backside of the dragonskin face so are never visible but I want it to look good everywhere if possible so...

[img]Untitled by Josh Beckett, on Flickr[/img]
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Beckett ()
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Joined: 22 Oct 2015
Posts: 156
Location: Oregon, USA
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PostPosted: Fri Jun 29, 2018 3:16 am    Post subject: first mask mold attempt Reply with quote

Well, having salvaged our plug (or so we thought) we set out yesterday to make our first face skin. to say that we ran into problems might be an understatement. First, we weren't sure how much material to pour to get the mask full. So we started with 10 oz. (about 50/50 Dragonskin/Ecoflex) and then ended up pouring more like 25 oz. (way more than I expected). Not to mention the fact that we were using material that was old (I guess). Anyway, between mixes we noticed that the material we'd already mixed started setting up. Not really knowing what to do and expecting to lose the skin we just poured more and went with it. Fast forward about 6 hours later we tried pulling the plug to see what kind of skin we had (fully expecting it to be garabage). BOY OH BOY! the plug we thought we'd reinforced (not so much) started crackng and breaking. Turnes out we should have just scrapped it and started with a new plug. So, we finally got the plug out with very minimal damage to the mothermold (phew) and this is what we had.

Anyway, the lip of the plug took a beating so it is scrapped.
[img]Untitled by Josh Beckett, on Flickr
[/img]Untitled by Josh Beckett, on Flickr

As for the skin. It actually turned out better than I expected given the garbage it looked to be when we finally closed the plug down and decided to just cross our fingers and go with it. It had some large air pockets in it that are a major problem.
[img]Untitled by Josh Beckett, on Flickr
[/img]Untitled by Josh Beckett, on Flickr

The good news is that we still have a mothermold so we don't have to completely start from square one. With that we decided to just re-line the mothermold with clay (this time we made it thinner (1/4'....which I thought we'd done last time but apparently my sidekick got a bit rambunctious). Then we sprayed it with release and did a massive amount of fiberglassing to try to get as strong a plug as we could.
[/img]Untitled by Josh Beckett, on Flickr
So. we'll wait for that to set and then hopefully this will work. So, far I'm not really liking the Epoxacoat mold. Chalk about $100 in material up to learning curve. Oh well, I suppose this is the type of stuff all the mask makers have gone through in learning how to do this. We'll get it figured out eventually.
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Beckett ()
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Joined: 22 Oct 2015
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Location: Oregon, USA
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PostPosted: Wed Jul 04, 2018 6:54 pm    Post subject: Fixed Plugand first skin pull from it Reply with quote

When I last posted my brother and I had just dealt with losing our first plug (made of resin) and when we tried to pull it from the mothermold we ended up losing the plug so we made a new plug, this time of just fiberglass and left it to cure for the weekend. Over the weekend we were up in the Seattle so I didn't think much of the waiting Tarfful plug until the drive home. I have to admit that I was pretty nervouse about losing another plug and, subsequently, our mothermold and then having to start from scratch on a sculpt. As luck would have it, the plug came free pretty easily in comparison to the last one that cracked everywhere and I'm happy to report that we have already made our first skin. It's absolutely gorgeous too! 1/4" everwhere. Honestly, it is amazing. So we went from thinking worst case scenario to really just feeling like we couldn't be any happier. The mold and plug are incredible so I think we'll likely end of doing Chewbacca the same way.

[img]Untitled by Josh Beckett, on Flickr

[/img]Untitled by Josh Beckett, on Flickr

Today we'll set our sights on making our first Tarfful underskull.

Happy 4th of July to those people that celebrate it!
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Beckett ()
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PostPosted: Wed Jul 11, 2018 1:19 am    Post subject: First underskull Reply with quote

laid our first underskull for Tarfful today [img]Untitled by Josh Beckett, on Flickr
[/img]Untitled by Josh Beckett, on Flickr
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Big Bear ()



Joined: 01 Mar 2016
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PostPosted: Wed Jul 11, 2018 9:12 pm    Post subject: Reply with quote

This is just amazing to watch. Thanks for sharing the journey with us!
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gato ()



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PostPosted: Wed Jul 11, 2018 9:34 pm    Post subject: Re: first mask mold attempt Reply with quote

Youre doing an awesome job!! Ive experienced the cracking noises of the plug everytime I pull a skin. I keep going back and reinforcing it and adding foil tape to the flange to make it stronger then covering it in fiberglass. Im using mold max release before adding the silicone, then once cured, Im inserting flathead screw drivers and turning them to get some separation to pull the plug and the mother mold apart. It has been working pretty good since I figured out a system.
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Beckett ()
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PostPosted: Thu Jul 12, 2018 12:41 am    Post subject: Reply with quote

[quote="Big Bear"]This is just amazing to watch. Thanks for sharing the journey with us![/quote]

Thank you for tuning in. I appreciate the kind words.
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Beckett ()
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Posts: 156
Location: Oregon, USA
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PostPosted: Thu Jul 12, 2018 12:45 am    Post subject: Re: first mask mold attempt Reply with quote

[quote="gato"]Youre doing an awesome job!! Ive experienced the cracking noises of the plug everytime I pull a skin. I keep going back and reinforcing it and adding foil tape to the flange to make it stronger then covering it in fiberglass. Im using mold max release before adding the silicone, then once cured, Im inserting flathead screw drivers and turning them to get some separation to pull the plug and the mother mold apart. It has been working pretty good since I figured out a system.[/quote]

The cracking sucks. The new plug that’s all fiberglass doesn’t crack at all so we are VERY happy with it. Just pulled the first underskull today and pretty happy with it. So at this point we can make Tarfful skins and underskulls. Now I just need to get going on the teeth.
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Beckett ()
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PostPosted: Thu Jul 12, 2018 6:49 am    Post subject: Underskull!!!! Reply with quote

I hate the smell of fiberglass resin!!! and I do mean HATE!

Anyway, pulled the underskull out today and it looks great. Worked on cleaning it up around the edges and then in the evening did a rough cutout on the eyes. Still thinking its amazing.

[img]Untitled by Josh Beckett, on Flickr
[/img]Untitled by Josh Beckett, on Flickr
[img]Untitled by Josh Beckett, on Flickr
[/img]Untitled by Josh Beckett, on Flickr
[img]Untitled by Josh Beckett, on Flickr
[/img]Untitled by Josh Beckett, on Flickr
[img]Untitled by Josh Beckett, on Flickr
[/img]Untitled by Josh Beckett, on Flickr
[img]Untitled by Josh Beckett, on Flickr

I'm hoping that tomorrow we can start doing the cutouts for the teeth and jaw hinge. My brother has become the underskull specialist so hopefully I can pin him down and he can make quick work of it. So much progress this week. [/img]
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