Hello this is going to be a step by step process in how I make some of my mask, mainly the army of two mask.
Step 1: Getting Ready
While playing the game Army of Two I was noticing the masks the charters had on, I was wondering if there were any out there? I found some but they were all for air-soft or paintball and had mesh covering the eyes and I knew that would not do. I did some looking and found a pep file. I figured that it would work for what I needed it for and started work on it. I printed it all out and started cutting and gluing.
Step 2: Starting the Process
I next had to put a couple coats of fiberglass resin and fiberglass. I tried to keep the bondo in small patches so that I would have more time to work with it and put it in thin coats. I started with the bottom half I figured that if I did it in two half's that i would always have a dry end to hold.
Step 3: Refine Time
once I sanded down the bottom half I started on the top half and sanded it down as well. after that it was time to fill in the nooks and crannies. after I was happy with the smoothness then I Put a coat of fiberglass resin to get into the small cracks and give it a smooth gloss to it. once that was done I started marking out the slots for the snaps to connect it to the back harness that I am making to hold it to my head.
Step 4: All Most Done
After I had marked out some rough spots I went ahead and put a coat of primer to see all of the ruff spots, and sanded them down smooth as butter. I wanted to make a mold of it so I could make multiple masks fast. so i started building up the silicone on the mask. now I have never made a mold of anything so this is was a learning experience.
Step 5: Casting Time!
I had to make a mother shell to hold the silicone in place for casting. I wanted to start my spring break of right, with making my first ever resin cast! I decided to make a cast of my army of two mask so I could try some different painting ideas. I started by making a silicon mold of the mask. I went out and got some aluminate. (sorry for the Terrible pic), and then I went to shushing, when I was satisfied with the thickness of the cast then we wait for drying time which was only 20 minutes so very fast working time.time to demold I went ahead and put a thin coat of primer to cover up the boo boos. and from there I was done and satisfied with my cast time to make three more. (left is master)(right cast piece)