Mold was made with rubber latex. It's a lot slower process than silicone, you paint thin layers of rubber latex onto the piece over several days. When the latex mold was thick enough, I made a hard case in plastercloth to hold the shape:
Resin was poured into the mold and rolled around to make a hollow headpiece. In order to strengthen the ears, I added some rigid expanding foam:
Finish headpiece removed from the mold:
In order to clean up some of the mis-cast errors, I used bondo to fill pocks, then sanded down the fills to a smooth finish:
The head was added to a headdress. The headdress was made with twisted 16 gauge wire, and covered with twine to look more natural. I installed some strips of sheetfoam to the inside of the headbase for comfort:
Next up.... painting!
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