Majora's Mask is my all time favorite Zelda game, so I guess it was only natural that I make Majora. This project is the culmination of several months of on and off work, due to school and work. I am extremely pleased with the results I ended up with. I learned how to make this as well as other props I have in the works through classes at SCAD.
Check out my blog to see more... http://boundclockprops.blogspot.com
Shoot me a private message and if enough people are interested i'll make a production run of a few castings.
Step 1: The Beginning
I began this project with a really basic computer model in Rhino to give the general size and placement of everything. After generating the CAD model I separated the parts into different layers mostly for fun so I could get a sense of what it looked like. While in Rhino I split the main structure into three segments horizontally so I could print off a top view of each piece and place it onto layers of pink foam and make the structure for real. Then took these templates with spray adhesive and glued them to layers of pink foam. I then took them to the band saw and cut them out. The next step involved stacking them (using more adhesive) and sanding away until i achieve the shape I wanted.
Step 2: Main Shaping
Now most people know pink foam is good for doing ruff shapes and has no real permanence especially with the introduction of solvents sooooooo I coated the foam with a layer of my favorite material of all time... epoxy putty, specifically in this case I used Apoxie Sculpt.
Next came the fun part (I jest since bondoing and sanding takes a long time and is very repetitive) I apply a layer of bondo to the surface to even it out, followed by immense amounts of sanding, then repeated this process several times. I followed the final sanding step of bondo with spot putty to fill in the small gaps, then of course sanded that smooth.