I haven’t posted for a while as most of June has been spent working on my new costume and moulding/casting and painting up a set of Darth Nihilus masks.

With the modified first mask ready, I created a new mould and tried my hand at slush casting using Smooth-On 300 resin. This is the first time have I tried this and used far too much resin on the first attempt. Taking a moment, I worked out how much resin to use, but still had a few problems due to the eye-holes and the shape of the mask. Eventually I got the hang of it and cast up four good copies which I have sanded and started painting. These will be painted in the original white/red and silver and I plan to put these up on my Etsy store when they are done.  White mask

Between doing these casts I painted the mask from the original mould for myself. Rather than the white, I went for a different look, using silver as the base with red markings and black down the centre. Although it wasn’t intentional, when done it reminded me of the colouring of Phasma’s armour from The Force Awakens.


Work is still slowing progressing on my costume. I have managed to speed up the process a little by stuffing the under suit; this makes sewing the bandages on much faster, though it is still a time-consuming process.

I will put up a blog post and on my Facebook page when the masks are ready to go on my store page.


I did some more work on my costume this weekend. First I finished off the waist section and sewed on the 2 layers of skirts.

Next up was sewing the bandages to the under suit. The ones I made last week looked great after drying, but I was having difficulty attaching them since they don’t stretch. It would be easy sew them and make them form fitting if I had a body cast or mannequin. After some thought, I decided to create some more bandages using some left over dye, this time using stretchy fabric I brought for a past project. These could be sewn straight over the under suit, stretch and not be too tight when it is worn.

Since this is going to be a lengthy process I will post progress on my Facebook page. Rather than short blog posts.




Dying to do something new

This weekend saw the start of a new project; this time it is new costume. This does not mean I am abandoning my Soliare costume; this is (hopefully) just a quick project I aim to get done in about a month. I will then continue with my other projects, such as the large sculpture I began, the sword which is still printing and moulding the mask with the silicone I brought.

The character is Nox the Time Wizard from a French anime called Wakfu. He is basically a mummy with a few pieces of armour with some light up parts. He does use a sword sometimes but I plan on only doing the costume at this point.

It will consist of 3 main parts:

  1. An under suit with bandages. This will be made from jogging bottoms, a long sleeve t-shirt, white gloves and a balaclava with linen bandages sew on. This also includes some old trainers I will also cover in bandages.
  2.  A helmet, chest plate and greaves made from foam (and possibly worbla) with working lights. These will Velcro to the under suit.
  3. A central ‘belt’ from which hang two fabric ‘skirts’ and a loin cloth. This will velcro to the undersuit.

I began the project by gathering two A4 pages of reference images and then working out anything extra I would need. Searching online I got quite a few bargains, managing to find the parts for the under suit, linen, Velcro, Led’s and coloured acrylic for less than £50 ($67).

Everything arrived ready for the weekend, which was spent cutting up linen for bandages, testing dyes and then staining the bandages. I also created the loin cloth, sewed the under suit together and started work on the ‘belt’ that would support the loin cloth and skirts. It’s off to a pretty good start.

Finished up

I finally finished the mask this weekend and I’m now happy that it as symmetrical and smooth as I can make it. Next up is to order another batch of silicone to recast it and make a few copies.

I also got close to finishing my scabbard, which only needs a little more sanding and filling before painting.

Lastly some of my time was taken up with an issue with one of my 3D printers when it got blocked. This occurred just above the nozzle in a gap that I was unable to reach and pull out. Due to this I attempted to drill out the plastic with a small bit This seemed okay at first but I must have drilled to far and the end of the nozzle cracked. I have now had to order a new one to replace it. I can then get back to using both printers to produce my sword.


Sand and fill

I was away at the end of this week and only managed a bit of making.

I began by assembling the parts of my sword I had printed so far including the pommel and grip (not in picture). Any parts that hadn’t been sanded were done and the gaps were filled. I did the same with the scabbard, which hopefully I should be able to finish next weekend. Having sanded and sprayed the mask, I noticed a one last issue – the right eye socket was slightly off. This was fixed with some 2 part putty, when this has been sanded it should be done.


The week of making

This week has been a holiday for me and I have spent a good amount of it being creative and working on various projects.

At the end of last week and the beginning of this one I finished modeling a sword I

At the beginning of the year I doodled some sword designs in a sketch book. It think there were about 8 or 9 in total. I wanted to make one of them but couldn’t decide which to do and so asked my friends which I should make. Below is the one that was most popular, now referred to as sword 8.

Sword 8

Rather than Balsawood and worbla I chose to go with 3D printing. At the end of last week and the start of this one I modeled the design and broke it down into parts. I also add a space inside the sword to slot in a 4mm/1metre rod for added strength. With the design finished I have begun printing off the parts and sanding them between working on my other projects.

Getting distracted by a new project idea seems to be one of the problems I’m encountering a lot recently. An example of this is when I watched a video from Punished Props which came out on Monday. This video is a tutorial on how to make a foam skull from Sea of Thieves, which has a downloadable template available. Well I couldn’t miss this chance to try something different and ended up making one. Mine didn’t turn out quite right, but I had lots of fun making it, plus I finished it and can carry on with other things. The video is below if you want to try your own.

Work is almost done on the Sith mask having done all but a bit of the filling/sculpting. It just needs a bit of sanding and it should be ready for casting again.


Straight Sword

This weekend and the last were mostly spent on trying to complete the Sunlight Straight Sword. This was going pretty well until I started to get bubbles on the surface of the sword. Not 100% sure how these occurred, but it may have happened between layers or from friction: these only became visible when I applied some Rub and Buff to the sword.

So I went back and sanded the blade section back down and filled any bubbles after popping them. I was also concerned about the amount of  marks I was getting as the Gesso is a little soft. To prevent this I mixed up some resin (XTC 3D) and applied it with some cheep sponge brushes – this is a great way to apply it to a flat surface. Not sure why I didn’t try it before as it minimizes the brush marks and therefore sanding. After three coats I sanded the resin lightly using 180, 400 and 600 grit sand paper. This gave a beautifully smooth finish and no bubbles in sight. So I used the Rub and Buff again and got 2 bubbles GRRRRRR 😡

Although previous projects using Gesso coat have come out okay, following this, I’ll only use resin coats in the future.  Although they can take a little longer to dry (4 hours each layer), only 3 -4 coat are needed, the finish is more durable and smoother. This along with the Rub and Buff gives an almost mirror finish to the blade. Overall, apart from the bubbles, I happy with the way this turned out.

Next up I will be finishing the scabbard (using resin coats) and the mask I have also been working on.



Oooooo Shiny


Annoying bubble