I was asked to create a life size 1:1 Face of Boe for Montreal Comicon back in 2014-15 for the Masquerade with my friend who would cosplay a great cat Nun.

I was hesitant as I was not sure how to make such a large prop and how would I transport it.

I thought that spray foam would do the trick and would be easy.....never again.....

It was fun but wow heavy and lots of spray foam.....

Step 1: Materials and Planning

So I planned my build based on some pics and chose the materials...my friend would make the eyes which turned out amazing....

My expectation on this one was low as I had no idea what I was doing and I knew this was not going to be an accurate build but perhaps from a distance it may look like the FACE OF BOE!!!

Materials:

10 cans of spray foam

cardboard sheets

mesh

nylon stockins

newspaper

bronze spray paint

light brown paint

white printer paint

tape

Velcro strips

lots of patience and crazy prop building

Step 2: Building....

So I traced out the face on cardboard, then trimmed out the shape. Then I formed out of mesh the nose and other parts of the face...

Step 3: Spraying....

Then I started to Spray on the mesh parts and the rest...I did not realize how many cans I needed....I forgot that I also used some gap fillers in between the foam....5 tubes later.....oh man this was crazy!

Step 4: The EYES....the Skin....

So I got my friend's prop eyes build for Boe which were clear Christmas balls painted...the light shone through and it looked fab....I install them in the back which was cool. I also layered some plaster strips over the foam to create the skin. Then I primed and painted the face outside....it was heavy...