u/Plus_Turnip_8235

Heres the finished mask, with fur hood..i know the fur isn't exactly the same as the original, but it's what I had available.

Still not sure I have the silver looking correct, but it will do for now.

So the painted Frank i cast by first painting a liquid Mouldcraft Fast Cast Polyurethane Liquid Plastic Casting Resin in the mould, which would become the outer coating, this was difficult, as it cured really fast and became unworkable within a minute. Because the mould is big with so many recesses and details to capture, it took several batches of the plastic to cover both halves on the mould..i then poured the liquid casting foam in the front half of the mould and quickly put the back on and tried to hold the two halves tightly together as foam started spewing out around the edges. This did work but the seams around his ears ended up too wide and not properly covered as the mould wasnt clamped together enough.. so..2nd attempt, I cut a filler hole in the base of the mould just under frank's bottom jaw, big enough to pour the liquid foam in, and bolted the two halves of the mould tightly together. I drilled various holes in inconspicuous places to allow air to escape, turned the mould upside down clamped in a vice, and poured the liquid casting foam in. As you can see from the second photo, this produced a much better result, the mask was much lighter in weight and the surface had a more matte finish. I believe this was probably how the original was made, rather than having the plastic outer coating. Unfortunately, i made a couple of mistakes. Firstly I didnt know the foam needed sealing first before painting. I tried some spirit based silver paints, which ate into the foam and ruined it..also the mask started collapsing in places, which I researched and discovered its either to do with not mixing the foam properly, or taking it out of the mould too early, or the humidity of the atmosphere..i suspect that its probably the fact that I did take it out the mould as soon as the foam had hardened, apparently the foam sells are still forming and havent properly cured on the inside. Also its been very hot and humid here in the uk, so that doesnt help... so, now I've a better idea of how to work with foam, I have ordered some more, to do a 3rd casting..hopefully this will be the diffinitive version. I'll upload some pics of that when it's complete.

Here's a quick video. I've very quickly painted it, so its not quite finished yet, still have to paint the eyes and teeth with another coat, plus gloss..and obviously the fur, which will come later..i plan to make the whole costume.

I had to make Frank's ears bigger, as I realised after much staring at photos of the real mask that I had sculpted them too small in proportion to the face. I painted it to see how it looked. Frank is now ready for the silicone mould process.

I spent the day getting a bulk of the work done on my second Frank sculpt. It's not quite finished, but it's getting there

I'm attempting a second sculpt of Frank. My first attempt (pictured) i cast in Uruthene rubber, and it's really heavy..when this new sculpt is finished I'm going to try the Uruthene foam as I understand its a lot lighter..at the moment I'm trying to find as many refference photos as I can of the original mask.