Adventures in mask-making

[Sir Masksalot]

Episode One ~ Paint

The "Calendar" Mummy has always held a hallowed place in my dark heart.
It's the first custom DPS mask I ever owned as a boy. Santa Claus must've
thought I was especially nice back in 1966 >



Fast forward thirty-four years >>
As production on the DP reissues was winding down, I happened to come into
possession of a version "A" Mummy direct from the factory. It was only partially
painted and its neck was badly distorted. Thickly cast as it was, no hope remained
of setting it straight again so I trimmed most of it away >



Also on hand was a factory original I'd purchased retail. It must've been there as
a color guide for, you see, my plan that day was to complete the paintjob on
this base-coated casting >



It was my good fortune to command the services of The Mask Doctor on this project.
He mixed up a batch of paint very similar in color to the DP original and dabbed it on
lightly so as not to cover over any sculptural texture >



I wanted the hair coated in such a way that it looked less matted than factory stock.
By the time we set the mask aside to dry, I could hardly contain my excitement.
Every copy in the edition should've looked like this!



I stuck a glass eye in it and later fashioned a base with tattered cloth strips >



Today it's the bust I display at conventions as part of my Classic Monster exhibit >



Reply with images of your custom finished masks. If you have before and after pics, that's even better!

[michblk]

What's the mask Doctors name?  He looks familiar.

Brian K

[Kidagain]

Kelly Mann.

[Dr.Terror]

Ahhhh.  The neck was trimmed.  Always wondered how you got your display to post that way with the long neck.

[michblk]

Kelly Mann.

Thanks, I've met him, just couldn't place him. 

Brian K

[Wolfman]

Kelly Mann.

You have his contact info? My DPS Glenn Strange Franky needs a new paint job.

JP

[Kidagain]

Kelly(*at*)Maskdr.com

[Sir Masksalot]

Episode Two ~ Hair application



It's usually the final step in completing a custom mask >

     

Our featured subjects are the hairiest of all: GORILLAs!



This particular version calls for fabric fur which requires patterns be cut >

     

Since the hair pieces need to flow into one another, we must start at the bottom
and work our way up. The neck and chin pieces go on first >



Next, the side pieces >



Lastly, the top >



This post is a very condensed version of a lengthy and complicated process, not to mention messy, but
the benefit is that whoever takes it on is most always the first person to see a custom mask completed >






 

[Doh!]

Thanks for the hairing tutorial, Sir!

[Sir Masksalot]

Episode three ~ Foam-filling

It is to rubber masks what linen-backing is to vintage posters.
There's no better way to preserve either of them for the ages.

Our subject on this Eve of MayDay is an "Old Hag" mask from Topstone >



The first thing to do is seal up those big eye openings to contain the liquid foam once injected >

     





With the seals secure, there should be no risk of leakage as the foaming stage commences >



All that excess foam bulging out the back will be trimmed away later >



First, we'll need to tunnel out a core just wide enough to admit a support post >



With the post firmly embedded, we can move on to finishing touches >



These involve planing the excess foam flush with the back and using a sticky tape
to remove any loose crumbs >



A stipple coat of latex is applied to keep the cut foam from crumbling any further >



We'll black the post, mount it on a base, and call the job complete >



This "Old Hag" should now survive many more Walpurgis Nights than we ever will. Have a witchy one!

[Wolfman]

Kelly(*at*)Maskdr.com

Thanks!

JP

[MonsterBaker666]

Another way to foam fill it is to put masking tape, wide cellophane tape or Duct Tape inside the mask (if the mask is new and not old and brittle), and then foam filling it.  This ways you can remove the mask from the foam and not have it adhere to to rubber mask.  Carefully pull the rubber mask away from the foam / tape, then remove the tape and put the mask back on it.  This way the mask can be removed for wear, if so desired.  I find cellophane or masking tape works best for me. 

[Hepcat]

The "Calendar" Mummy has always held a hallowed place in my dark heart.
It's the first custom DPS mask I ever owned as a boy. Santa Claus must've
thought I was especially nice back in 1966 >

Wow! How did you get your parents to spring for a hideous, not to mention expensive, mask?

 

[FRANKENSTEIN455]

Thanks Sir Masksalot for the always interesting and informative posts.  The Don Post Mummy A came out beautifully.  The coloring and hair work look fantastic.  I wish they had used this style in the actual production pieces.  The photos of the hair applying process and foaming procedure intrigue me.  The photos make it much more understandable to us artistically challenged mask lovers. The Delgado Gorillas came out beautifully. It looks to be a very complex and precise procedure.  The Henry Alvarez Jack Nicholson mask is also such a cool piece. I always thought it was a fantastic likeness. Thanks again for the great process photographs.

[Sir Masksalot]

Wow! How did you get your parents to spring for a hideous, not to mention expensive, mask?

Mother was totally against it but Dad must've gotten tired of my constant begging and whining.



Incidentally, three vital episodes in the creation of rubber masks are missing from this thread:

Sculpture >



Mold-making >



Casting >



My experience with all three is somewhat limited so if anyone here
would like to cover them for us, I welcome your contributions.