Update! She-Ra costume on ebay starting wed September 12 2007. Bid now!
Love , Love, Love Halloween! This is without a doubt my favorite time of year. My She-Ra costume last year was pretty cool, ,but this year I’m raising the stakes! Bring on the Headless Marie Antoinette! How will I accomplish this you ask? Well, let me tell you now.

Start with the idea. From this drawing you get the idea of what I’m after. Pretty cool!

To begin this project, I am starting with sculpting the fake bust I will need to create the illusion of a decapitated body. I used a raku clay that is very easy to work with and dries fairly fast. I am using the jar as the “neck” because I dont think I have enough clay.

OK, here’s the almost finished clay bust. The boobs took some work because I wanted them very fake and baseball-y. They should look like their being pushed up by a corset.

Now here’s where it starts to get tricky. I need to make a negative impression of my clay model, so that I can create another foam positve. To do this I will cast my clay bust with plaster of paris. Firstly, I coated my clay in vaseline to prevent it from bonding with the plaster. (in retrospect I’m not sure if that even worked but better safe than sorry)
I created a clay barrier that ran just off-center of the bust. Then I poured the plaster over one half of the bust up to the barrier.

After the plaster on the one half was set, I removed the clay barrier and coated the inside edge of the plaster with vaseline. This is to prevent the second application of plaster from adhereing to it.

Now here is where I ran into some trouble. I had anticipated being able to pull my plaster mold off the clay model in two pieces.
However, the mold did not want to budge. The clay seemed to have suctioned to it and i couldn’t force it off. So I ended up having to dig out the clay in chunks from the bottom. Good thing it didn’t really dry. So whatever, ther end result was the same.

I reconnected the two parts of my mold with saran wrap. Then I poured my liquid foam in. This is the same foam I used last year with my She-Ra costume. This is a Urethane Foam from Smooth-on. Oh, I almost forgot. I had to seal the interior of the mold with chemical sealer, and then coat it with a release agent. This prevents the foam from sticking to the mold.

The foam expands and cures in about 30 min. Looking good so far!

NIce! As you can see, I was able to extract an almost identical foam model to my original clay sculpture!
Next I will next paint the foam and start work on the rig that hold it above my head.
later n