Vakuumforming a NCR Ranger Mask

This is the result of a little group project.
A few people offered a budget to make 7 of these masks under 100€ a piece... if you know how.

Step 1: An Idea

At first we have to gather informations on the size and proportions of the prop to make.
The game is quite old so there is more than enaugh material on the net to get some inspiration

Step 2: Making Models

I built a basic version of the mask years ago and filled the gaps with clay. After the positive was ready I covered it in petrolium jelly and sorrounded it with some tinfoil. When you are making a mould from epoxy you have to mix it with some thyxotroping agent till it is thick enaugh to not run down on the sides.

Step 3: Vakuforming!

Step 4: The Rest

Rinse and repeat.
Ofcause if you find some parts better in the internet use these ressources to your advantage (like the helmet).

Step 5: Start Connecting