In this Instructable I am making and applying a full face foam latex zombie prosthetic.

Step 1: Sculpting

I sculpted the prosthetic over an Ultra-Cal 30 lifecast using Monster Clay, dental carving tools, and a few loop tools.

Step 2: Molding

I started molding by using cheap oil based clay to make the flange and mold wall, then I sealed the exposed Ultra-Cal with mold soap. Once that was dry I mixed up a slightly runny batch of Ultra-Cal 30 and brushed it into all of the detail. After about 45 minutes, I mixed a second batch and saturated some pieces of burlap in it, then I put the saturated burlap onto the zombie face. For the third and final layer, I mixed up a thicker than usual batch of Ultra-Cal 30 and brushed it on.

Step 3: Casting

To cast the prosthetic, I started by lightly coating the positive and negative molds with monster makers foam latex release. Then I mixed up a batch of foam latex, following the monster makers instructions. Then I carefully brushed the foam latex into all of the detail, poured the rest of the foam latex into the mold, closed the mold, and used a mold strap to hold the mold tightly together. Then after about 15 minutes, once the foam had gelled, I placed the mold into an oven that was preheated to 170 degrees farrenheit for 3 hours.

Step 4: Applying

I started pre-painting the prosthetic by coating it with pros-aid, to seal the foam latex. Then I used Skin illustrator and several different RMGP's, rubber mask grease paint's, to paint the prosthetic, starting with the lighter colors and working my way to the the darker ones. Then to make the gums and teeth shiny, I brushed on a thin layer of polymer medium "gloss".

For the application, I began by brushing Pros-Aid onto the inside of the prosthetic and on my sister's face. Then once the pros-aid was dry I carefully laid the prosthetic down on to her face, starting with her nose and working my way outwards. The next step was to coat the edges of the prosthetic with pros-aid, trying to hide where they end. When everything was dry I used many layers of color, including skin tones, reds, blues, browns, and yellows.