First Dragonskin Castings

This is to describe the steps I took in making simple rubber shapes which I intend to use as cosplay belt buckle pieces; they won't be working buckles but rather attached to vinyl belts to give that classic superhero look (like Superman's simple yellow oval).

After experimenting with Flex Foam 3, I decided to try a different rubber compound for my belt buckle castings. My friend at Smooth-On, Jason recommended their Dragonskin product (you've probably seen it used on Mythbusters). It's a two-part equal ratio mix. It can only be pigmented not painted so that was also a new thing for me to try. The Silc-Pigs are pricey but a little bit goes a long way so it actually works out to be a relatively inexpensive thing when you break it down.

To begin, I wanted to go with simple shapes. I think I was trying to run before walk when I sculpting with wax and making molds for F4 and Tech Support. I pulled myself back and bought things in the shapes that I wanted: the circle was a 3" metal button from the sewing department of my local craft store; the oval was a cardboard oval container with a lid which is the part I used. I used a cardboard box as my mold container. The box had a layer of masking tape inside and then smothered with petroleum jelly. I used the duoMatrix Neo instead of gypsum for the mold. It's great to work with even for a beginner like me.

The Dragonskin is great because it's a 1:1 ratio and I don't have any precision measuring devices or scales. I basically eyeball stuff that I mix. For this project, I used a small cup that I would guess holds an ounce of liquid; first poured in the A part, dumped it into a paper cup, then poured the B part into the small cup and added that to the paper cup. With no expansion, it's much easier to handle than the foams and you can take the time to mix and pour whereas the foam dries within seconds. Then comes the pigment - I just used a popsicle stick to dip into the Silc-Pig and then just used that stick to continue mixing the Dragonskin. It took maybe a teaspoon at most to color my two ounce mixtures.

I sprayed my mold with Krylon's Crystal Clear before pouring the Dragonskin. The spray dries quickly within 15 minutes. When I did the blue ones, I added one step: to the circle mold, I lightly brushed a layer of Cast Magic Goldfinger casting powder to added a gilded look to it.

I think my yellow castings came out best. When it came time to do the blue then red, I found that I should have let them set a lot longer. My blue and red oval shapes are a bit "chewed" up on the sides because they weren't ready to be demolded. My circles are really good but I noticed that they are lopsided from a side view because using my washing machine as a work surface is not at all level. However, for a costume piece, I actually don't think anyone would notice this.

Since the hero I'm working on next has a plain buckle, I don't have too many ideas yet for how to get more complex in my casting. I think the first one I will try that's more than just basic, will be the Legion of Superheroes logo.

Continuing with the plaster

It's a good thing I'm not a neat freak. I have been playing with my hydracal (plaster gypsum) today in my teeny tiny laundry room. I was able to sand a decent amount of my Tech Support wire globe logo with the Dremel. Then I brushed a new layer of plaster over it trying to make it nice and smooth. Well, it sure looked nice when it was wet but now brush strokes are severely showing.

I'm going to a different approach to the Fantastic 4 logo as well. I had let some of the plaster harden in the bottom of the bucket I used last time. I was able to pop it out with some muscle. The only thing is the bottom had typical manufacturing divots in it so it's not a plain circular surface. I just tried brushing a new layer on but it wouldn't sufficiently stick to the smooth surface -- probably because I didn't sand it first. Oh well. Live and learn.

Invisible Woman costume update

Here's a CG mock up of what the costume should like when it's finally complete (on the right). Right now I'm working on the casting of the chest logo in Flex Foam and latex. The Flex Foam worked better much to my surprise. I really expected the latex to win. It was my first time doing any kind of moldmaking and casting so the fact that they suck isn't a surprise.

The top image on the left is the Flex Foam III with a very thin latex coating which happens to be peeling off.

The lower image is just latex. I have no idea why huge chunks are missing. There aren't any chunks left inside the plaster mold so I have no idea where they are. Even after two days, there were still parts of that outer circle ridge that were not cured but it didn't seem like it was enough to make those giant craters.

Overall, the costume is not very flattering for my figure. It will most likely be up for sale once it's finished without boots because it's just easier for people to buy their own size.

Moldmaking

Here's the progress of my moldmaking in different stages on two different projects:


Wireglobe logo in wax for Tech Support Fan Club (WWTBASH: S1). With any hope, I'll get a great master casting and can make lots of good quality latex logos. I'll set up a Pay Pal button and page to purchase this for Tech Support members.




Fantastic 4 logo in wax.









Fantastic 4 plaster casting waiting for latex which I just ordered from Smooth-On (with ridiculously expensive UPS shipping when I live close enough to go pick it up if they had that option).

yes, there's progress

We got to hang out with Joanna and Jason yesterday and see baby Bea for the first time. Then Jason and I got to play with plaster and start the mold casting process for my Invisible Woman costume chest logo. He gave me a lot of tips like add plaster to the water not water to plaster; use hot water with a little salt, and you don't need an expensive moldmaking box (we just took ducting tape and a piece of floor tile and make a containment area). It's humid today but I'm sure the plaster will be cured by this afternoon. Then comes the part of removing my wax sculpture from the plaster. Next step -- LATEX! Woohoo!

J is very encouraging and since he knows so many people in the special effects business, it's amazing that he thinks I be good at this. So... hopefully... (yes, another career possibility) I can get cranking into the latex casting business and make the things that people who just want to sew or purchase base items will need. That way, if you buy your bodysuit from a dance company and need a chest logo or badge, that means, I'll be able to supply that piece and you can just glue it in place. Yay for plans for the future! Huzzah!

I have also given more consideration to auditioning for Season 3 of Who Wants to be a Superhero? if there is one. I watched a few more YouTube videos of the Texas Titans (that's a bunch of people who auditioned for Season 2 and have stayed friends and make fun cosplay movies) and it inspired me. I have realized that there's no need to be nervous about auditioning because it's so unlikely that I'd get chosen. BUT, I'd be there and I'd be connecting with other fans and maybe a Titans East could be formed. Ya never know.