Ichabod: The Beak

I have built the beak with the same sort of relief decoration as the eyepieces.

This is the beak in progress with the lasered relief applique in the background.


Here is the final cast beak, showing both the side and bottom view, in cold cast aluminum.


And here is the beak on the plasticene sculpt, giving an approximatation of the final mask.

Ichabod: The First Sculpt

With the eyepieces done I move on to sculpting the mask in clay.

I place the two eyepieces onto the face form and start adding plasticene, which I've warmed in the microwave oven to soften it.

I build the beak up to where I think it should be. I'm not concerned about getting it smooth at this stage. I just want to get the proper proportions.

I use my clay tool to remove a layer of plasticene at the bottom of the beak, where the leather will lie over the resin.

And I cut off what will become the resin beak, and prepare to make an RTV silicone rubber mold of it.

Once the mold is cured I cast it in urethane resin and proceed to refine it. Sanding down the resin is easier to do then smoothing out the clay, and achieve a nice clean surface.

Dr. Beulenpest: Stitching the Leather

I've cleaned up the patterns and used them to cut out the 5-6 oz vegetable tanned leather pieces.

I begin by handstitching the two left pattern pieces together. I then repeated for the right side, then joined both halves together.

Here I've stitched on one of the eyepiece trims, and am checking how it looks with the resin beak and two eyepieces. So far so good!

I have stitched on the second eyepiece trim, as well as the surround that will support five buckles for holding the mask on the head.


This is my attempt at adding a leather trim piece to ease the transition between the resin beak and the rest of the mask. It's proving awkward to fit well, and I am thinking of other ways to accomplish this. I am also struggling with the resin piece that will fit between the two eyes. Hmmm, what to do, what to do.....