I had the idea of making a mask that would be reminiscent of a human skull. Below is my first sketch.
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjMiUWsS9EcRem7JzbO1xyWmwCXlXuGSnZCboPqHC4ZubMrRH8nDtpQGcK5spM6y7z7VK8xEGl1koyYfGyPIeTK63ju_PLeVF8IhmVkYyU3C4O56W5aBjX1y0Ngw47mXy-cppfCJGKer41r/s400/Sketch.jpg) |
First sketch of skull mask |
I had already made up some eyecages, similar to the ones used in the
Ragnarok mask, only larger, and I decided to use them for this mask.
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgW4AJG4WQkeYljFxi1Qce8iuqRVrV-ykIQ1hUU-mHdS8AhcyyrR8wXVpFYiMDjklt2uYzm6e2o8WImjbZLuLPvucKDjVbqiNaxOOsvz824lLQ4A2qQ1vCN_UKYmvoEChCXhEIS7oKSEs7T/s400/First+idea+in+clay.jpg) |
First idea translated into clay |
I wasn't sure at this point how I would make the teeth, but I was thinking of fabricating the part out of acrylic sheet and then casting it in cold cast aluminum, to match the eyecages.
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhHRINQE0YDgY7X7fCSZVE3_bqfq1DQ84yfPnLdq5xnWW_ygQz8lIThAQ6OEVTZQL9C4jOTTN-GFHQ21sed6_HzZpITjbWSMm-8fo5Gqk9iLh6r1AAj8fkcDL4NHbk9hJkUGf5N4rK_Ajyv/s400/Dog+muzzle.jpg) |
Dog muzzle |
After further consideration, I decided to look through my many boxes of yard sales finds, in the hopes of encountering a part already made that could be adapted to the teeth. When I came across the dog muzzle I realized I could dip it in wax to thicken up the wires, and give it a similar look to the eyecages.
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg_jkRqmuNlDt-bKUTo_1eVbZHQD3Ww35TefzLRVgFdnKhD1sxfV2mk3yQwJcu0Amlsan2-q7z8UHPThSMTPfp-p-NuoGM0G7xXGXLf6VcHlM0WgMkEVW5F0eFmnKh3nj-yUBHNHHEAYfvU/s400/Wax+pot.jpg) |
Pot of melted wax |
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEic648pePkqYQRGLIkEnS7x3Fcl3m-6oWzXP5trR-wzWVIPrteeYtQu7DYf0mMGetWdZpMp68XijM96Iknl2uU40UVst9hywJWedHDr8MQE5IERGBSl1kVt5M4Q-N4zy1AkGUe1hyphenhyphenSir7oG/s400/Muzzle+dipped+in+wax.jpg) |
Muzzle after being dipped in wax |
I heated the wax to around 220° F and dipped the wire muzzle into the molten wax, and let it cool down. Dipping it two more times gave it a nice thickness.
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjDeHttSk14wiDhexpzF0jxi1w0swxiWK8OBCH8dqWYg4lFKgL2K5DiHiFaHzQVK75WUsz_1Gu6paV6v4MCu5MeQpzweXXYZ-CKUtP86DmlihIo3m1vmZkoSgJzHpVW5LnEuSUSDsXQ8E5t/s400/cage-after-dipping.jpg) |
Muzzle casting |
After molding it in silicone RTV rubber, I cast just the top part of the muzzle in urethane resin.
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh9qxT8SHqpF2_ddIr5hkQoWVH30M2sqQzm0YSeUohyGkQYWHOhHdlFy7FNaq0jqhRnTKuKal5Kvv8PNWXrfApnRRSUUX6ZGtpC1h-kIGNbkRoO9JMl48zq3ttjB-rgtNKM62DOxxfefCDM/s400/Cage-in-base.jpg) |
Muzzle casting in mounting base |
Then I scanned the bottom of the casting, and laser cut several pieces of sheet acrylic to match. I used epoxy to stick all the pieces together, and filled in the hollows with modeling clay.
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgmRxlapDdSKJpYSb-ZFWWkoeeMOcQJNLB-vY_5g5oJWpLtaggsxFWO5zQ6VJKAVisQCr6u5uajeZOb2lZLtMNZulvXiGTe9tJCKG692LMJ32J1b1iwbITe8Zo5kQ8y0d4Jum89X3TuLAGq/s400/Sculpt-with-all-hardware.jpg) |
Clay sculpt with eyecages and muzzle |
I remolded the muzzle, and cast the finished part in a pink urethane resin, suitable for sculpting the final clay shape. Once I am satisfied with the shape of the clay I will take a pattern from it and then make the mask out of leather. It bears little resemblance to a skull now, but I am liking the look and am tentatively calling it "Uncle Charlie".