James Vaughan Meets the Minx...

...and here is the result.

I recently designed the Minx mask in red for the Halloween season. We also make it in all black. It is available on Etsy.

James Vaughan Photography blog

James Vaughan Photography on Flickr

Plague Doctor Mask Revised

I have altered the first pattern in several places to make this revised mask. I eliminated the center forehead seam and replaced it with two temple seams which extend to the eyes. In addition to looking cleaner it also allows the eyes to have more shape. I also added a dart to the underside of the beak so that it has a better curve.


The first picture shows the left eye being stretched open with an acrylic ring. I have also added tabs for attaching the straps with three rivets.

In the photo above I have stitched one eye lens with its leather trim into place. The darker leather is due to its being wet, which makes the hand stitching easier and lie smoother.

Plague Doctor Mask

I've recently had several requests for a Plague Doctor's mask, and as it appeals to my sense of beauty I've begun working out a pattern.


I particularly like this one shown above (which resides in a Danish museum) as inspiration, because the beak flows gently from the face, rather than looking just stuck on. Unfortunately it does have a major flaw in that the eyes are too widespread, and the wearer would scarcely be able to see out of it.


This is my first attempt, with corrected eye placement. I'll be adjusting the pattern in a couple of places and trying it again.

Eyecage Leather Mask

Here is the first one I am happy enough with to offer for sale. Listed on my etsy page. I think it has that nice creepiness to make it interesting.

Defender: Mask with Respirators

I have finally gotten the Defender mask antiqued black, and have the eyepieces in place. I also have the pair of respirators mostly done.


Every day it gets a little closer to being complete. I look forward to putting the mask and helmet together for a photo.

Defender: Mask is Dyed

Back to the Defender mask, I have now sewn on the trim for all four openings, and dyed it violet, prior to antiquing it black. One eyepiece is shown. I'm still figuring out what the respirators will look like.

Defender: How I Make an Eyepiece

I thought it might be interesting for some of you to see what goes into creating one of my resin parts. For the Defender mask I decided to make one of the eyepieces similar to a camera lens, with a stepped conical inside. I built the prototype in layers of 1/16" (1.5 mm) thick clear acrylic sheeet. The drawing below shows part of the file I created in CorelDraw.



As you can see, the outside dimension of each piece stays the same, while the inside hole decreases in size as we move down the page. Some of the outsides are zig-zag while others are smooth. The red lines are the cut lines, while the blue lines are just for planning. The tiny red circles are for alignment pins.



Here are the pieces after being cut out with the laser. The parts on the left were extras I didn't use; the ones on the right were put together with three pins, and sprayed white to seal the cracks.



I then molded the prototype with blue silicone rubber and let it cure overnight. The next day I cast it in a charcoal urethane resin. I drilled holes around the perimeter (that had already been marked with the laser) and inserted twelve rivets to make it a bit steamier. I then remolded it and cast it in black.



Here is the finished part with pewter Rub N Buff™ added to the surface to keep with my black and silver color scheme. I'm not sure yet if I will use this one or recast it in a cold cast aluminum.



The small ½" (12.5 mm) diameter hole at the bottom of the lens sits fairly close to the wearer's eye, allowing him or her to see out, while keeping others from looking in.

Defender: Adding Piping

To finish off the two eye openings on the mask, as well as the respirator openings I am stitching on leather piping. The mask parts are 4-5 oz leather, while the piping is only 2-3 oz, so it will more easily fold.



The pattern for the piping is a rectangle. Here you can see the piping piece at the bottom, and on one of the eye openings the piping has been attached. In addition to looking better, it makes attaching the resin eyepieces easier.

Defender: Starting the Mask

With the helmet nearing completion, I have begun on the mask. These two parts—the helmet and mask—could be worn alone, but they are designed to be worn together.



This is a variation of the gas mask, with two respirators on the sides of the snout replacing the single central one, which gives it an eerie alien look.



Each of the two eyepieces will be different. One of them will resemble a camera lens, and the other a porthole.



Here is a photo of the mask after the major leather pieces have all been stitched together.

Defender: A New Steampunk Helmet

Time to start a new steampunk helmet/mask. This one has a working title of Defender. My last project—the underground explorer helmet—was met with much critical acclaim.



Since it started with pulling a pattern from a simple toy helmet, I have decided to use the same technique for the Defender's helmet. This time the form is a Darth Vader plastic helmet that I found at a yard sale.



Here I have covered half the helmet in two plus layers of masking tape, and marked with a felt pen where my seam lines will go.



These are the two patterns cut off of the helmet and laid down flat on cardboard. Next I will adjust these pieces so that they will work in leather, then cut the leather and handstitch all four pieces together.

Underground Explorer: Oxygen Canister

I have had a good response to my writing competition. Seems like there are a lot of writers happy for an excuse to create a short steampunk story.

The final piece of the undeground explorer helmet is the oxygen canister which connects to the leather snout. Pictured below is the antiqued canister with rubber tubing and the connection at the other end.


Still to construct is the leather strapping which will allow the canister to be worn on the back or over the shoulder. Brownie points to anyone who can identify the original item from which the canister was made.

I leave for Maker Faire in San Mateo, CA exactly one week from today, and the finished helmet will be the centerpiece of my display.

Underground Explorer: Designing the Goggles

These giant sized paper glasses are my beginning attempt to work out the pattern for the goggles. This is going to take a lot of trial and error to get it right.

Underground Explorer: Lamp Comb is Finished

After focusing on the whale tooth for awhile I have returned my attentions to the Underground Explorer's helmet. Yesterday I reworked the comb pattern and remade it to fit properly, then I cut out the leather and hand-stitched it over the acrylic comb form. Today I painted it black, and antiqued it brown to give it that old look. After drying, I bolted and riveted the comb to the leather helm, and attached the lamp to the front.



I have decided on all of the design elements of the helmet, and have just two more to complete: The eyecover/goggles, and the oxygen canister which will hook up to the snout. With this equipment our intrepid explorer will be protected from extremes in pressure and temperature, as well as falling rocks. They will also have a bright light to see what lies before them, and have a fresh supply of oxygen to weather the pockets of foul air. Hopefully this will protect them from all unforseen dangers that might lurk ahead.

Space Helmet to Underground Explorer

The poll is over, and Underground Explorer won with exactly 50% of the vote. So I must prepare our courageous traveler for whatever conditions might await. Darkness of course, and probably heat, maybe pressure, foul air, unknown creatures, etc. Thanks to everyone who voted.

Designing a Steampunk Spaceman's Helmet

Today, Sunday, my wife and I went to some yard sales. Now sometimes you find nothing, and other times you find one gem. Just as we were about to leave one sale emptyhanded, I spotted a plastic astronaut's helmet. When I inquired about the price, the seller said $1--uh, 50¢--fearing I wouldn't cough up a whole dollar for this plastic helmet that was missing the visor. Of course, I saw much more in it. I knew I could pull a pattern off of it and remake it as a steampunk leather helmet!

Here is the plastic helmet as I bought it.

After thinking about how to break it up into separate leather pieces, I taped it all over with duct tape to make the patterns, and marked the divisions.

Here I've cut off the duct tape using an Xacto knife, and laid it down on heavy paper.

Next I've smoothed out the lines, removed the duct tape, and cut out the heavy paper patterns.

Next using the patterns I cut out the leather pieces, and punched the stitching holes, along with snap and buckle holes. I am leaving the front piece that covers the mouth removable so that the wearer can take it off for eating, etc.

Here I've stitched together the left center piece and the left side piece to see if it will work. I used a seam that exposes the edges, but after seeing it I think I'll remove the thread and do it over with an overlapping seam so that it will lie flat.

I will post more later as I progress on this project.

Designing a New Leather Mask

Spring is almost upon us, and leather mask sales should pick up as buyers think about what they're going to wear at music festivals. Above is my first sketch of an idea for a new mask, consisting of a whole bunch of cut out hearts. I drew this right before turning out the lights for bed. The star means I think it's a good design.

This is the next sketch the following day, seeing how it would work to have the eye openings be larger hearts, with other hearts around it. In designing a mask, the eye openings are critical.

Here I have fleshed out the idea, and after penciling in all the hearts on one half of the face, I have inked them in. Next I scanned this image and brought it into Corel Draw, where I fine-tuned it and mirrored it for the other half of the face.

And here is the finished mask, after cutting out the pattern in leather, shaping it to my face form, and painting it red. Lastly, I've listed it the Cut Out Hearts mask on Etsy, where I hope it will quickly sell!

White Rabbit Mask Makes it in the Pictures

Boudoir photographer Andrea Hausmann has purchased one of my white rabbit masks for use as a prop in her photographs. Hiding coquettishly behind the mask is burlesque cabaret showgirl Coco Framboise.

Custom Leather Mask for Rhymefest

I just finished a custom half-mask for Grammy Award winning hip-hop artist Che Smith, aka Rhymefest. His logo of a stylized R and F is in burgundy on a black background. Watch for him to wear it while he performs!

Pachydermos: The Photos

My lovely and patient wife agreed to model the mask. Above are the results.

Pachydermos is finished

The crazy steampunk gas mask that I've been working on for months is complete. Now I just need to get some good photos. Its official name is Pachydermos, which is Greek for wrinkled skin.