7ft Jack-in-the-Box Static Prop

Step 6 Trim - Skulls

Materials Used:
16 Plastic Skulls
1 can Great Stuff Foam
1 can Plastic Spray Primer
1 can Gold Metallic Gold Spray Paint

The plastic skulls were found at Joann's, a craft and fabric store. There were two types of skulls available, I was unable to get all 16 in one skull type, so I bought eight of each. I used a hand saw to cut the backs of the skulls off, to use as decoration on the trim.

The skulls had decorative black paint on them which easily scraped off with fingernails, so it had to go! Using a wire brush most of the paint was brushed off. The outside was lightly scuffed with sand paper.

The inside of the skull was filled using the Great Stuff Foam in a can, while according the can sticks to just about everything expect certain plastics, the same plastics these skulls are apparently made out of. After filling the skulls with foam and letting them cure the next couple of days, the foam started to shrink and was easily pulled out. I think this was due to a couple of factors: the smooth plastic of the skull, residue chemicals from the skull manufacturing and putting in way to much foam which inhibited proper curing. So I pulled the foam from the skulls, which worked out pretty well, I sanded the inside of the skulls to give the foam something to adhere. I also filled to skulls about half way with the foam and then set them face up on cardboard with a light weight on each skull. The weight was added so the foam would fill all of the voids within the skull. After the foam had cured, I tired to pull it out of the skulls and found it had adhered. Using a hand saw I cut the foam flush with the back of the skull, so I had a nice flat surface to glue the skulls to the box.