A short little video showing the new jawset and tongue in one of my resin heads.

Cool, huh??

To date I've purchased teeth from other craftspeople to use in my masks, but I've always really wanted to make my own. Below, a pile of attempts made over the past couple of years, made with Monster Clay (a kind of plasticine), Super Sculpey and Apoxie Sculpt.(Skully is supervising. He is a very helpful skull.) A whole lotta nope right here.

I finally settled on the Monster Clay for making the prototype teeth. I got tired of waiting for the other two to dry and/or set up in between sculpting sessions, and I got REALLY tired of trying to smooth out the hardened model with sandpaper or a Dremel. Monster Clay can be frozen to make it very hard and  can be softened with a hairdryer or microwave or such to make it very soft, so it is adaptable for a variety of sculpting situations. It also smooths beautifully using rubbing alcohol or its more powerful big brother, isopropyl myristate.

 

  

Above, looking to see how the lower part of the jawset is shaping up when viewed from the side. The teeth are just loosely stuck down to the gums at this point, so I can easily move them around if I need to.

 

And tada! Above, a finished Monster Clay plasticine model, ready for molding. Silly me, little did I realize that this would be the first of three finished jawsets I would mold. Sucks being a perfectionist.

Above, beginning the molding process, and a tongue while I'm at it. The jawset has been firmly attached to a thin piece of plywood, which will serve as a mold board. Every little gap between the model and the mold board is filled in, as otherwise the mold rubber could find its way under the model, and float the model up on top of it while it's curing. Which would not make a very good mold at all.

Above, getting ready to revise the jawset. Did I mention how I did this three times? Seriously though, it's easier to check the fit of the teeth in the head when they're in hard resin and not squishable clay. Above, a set of resin teeth that has been Dremelled down to fit the head better, and another set of clay teeth made by pouring melted Monster Clay into the mold, called a "borrowed casting". It's much easier to tweak the teeth from a borrowed casting than trying to make a whole new set from scratch. (If I wasn't such a chicken, I could have also resculpted my original set of clay teeth. But I wanted to keep them the way they were for extra insurance.) 

Above, revisions. To the right in both pictures is the original sculpt, still on the moldboard. In the middle is a modified resin casting, and to the left is the resculpted "borrowed casting". This first go round I removed the "flare" thingy from the bottom jaw, as it only really served to complicate fitting it into the resin head. I also made the plate for the upper jaw more symmetrical. You can see how the original sculpt has a bigger "bulge" on the left hand side than the right. Why did I do this, you may ask. Well, I was using a reject resin head casting to fit the teeth in, and I forgot that the resin on one side of the muzzle was much thicker than that on the other so.... in order to center the teeth in the opening, the plate had to be a lot wider on one side. Definitely not going to be the case with the average resin head! Fortunately I realized this before I got too much further into this process!  A great big duh, but could have been a much bigger duh.

Above, showing all three sets of revised teeth. The top set is the first one, the middle is the second and the set on the bottom is the final version. Besides changing the "plate" as described earlier, I did a lot of playing with the front incisors. I refined them in the second set but then realized I had also made the top ones too small, so I made them bigger in the third set. After re-checking my reference pictures of real wolves I also decided the gum area above the front incisors also needed to be longer, so I also changed that in the third set. I also did a lot of fiddling with the area circled in yellow in the right hand picture, with the way those particular teeth came together. The top incisor right next to the large bottom canine also underwent a fair bit of refinement.

And since I had spent so much time fiddling with the teeth, I decided to fiddle with the mold making method as well. At the suggestion of an acquaintance I made my next set of mold boxes out of Legos instead of Tupperware containers, so I could get the mold boxes precisely the size I needed them and save molding rubber. Molding rubber is expensive. They don't call it "platinum cure silicone" for nothing. (A good source of cheap used Legos is bricklink.com.)

 

Above, the nose and tongue models with their squishy rubber counterparts. Wheee!!!

Checking out the fit of the rubber nose in a resin head. Lookin' good! The resin head on the right wants a rubber nose too. 

And above, a pile o' puppy parts, ready for maskmaking!! I'm feeling good about the results of my endeavors here. Time to think about colors for fur!!

Below, a short video we made to showcase Maxine before her auction. Which never happened, as a visitor to the studio made an offer we couldn't refuse, and she went home with him. Still, it's a fun video, so we'll share it here. 
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I'm starting to get over my terror of airbrushing and look forward to it instead. It helps to keep in mind that if I find a new way to plug the airbrush up, and subsequently find a new way unplug it, I've learned something new and made progress. This particular go round I found that what I thought was one piece of the airbrush was actually two pieces. Paint can dry in there and plug things up. The two pieces unscrew from each other, and I can get in there with a dental pick. All is good.
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Above, Maxine before any airbrushing, modelled by Uncle Nathan and visiting with his two dogs. The dogs don't know what to think.

I was very happy I kept detailed notes on which paints I mixed to get the colors for Max, as it made coming up with those same colors for Maxine that much easier. Yay for notes!
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Getting there! In the homestretch with Maxine.
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Maxine before her shave and trim, left;and after, right.

​I was more aggressive pre-shaving the fur pieces with Maxine than I was with Max. Easier to sew pieces with shorter fur, and definitely easier to shave them when they're not glued on the head! 
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I also had a lot more respect for the clippers! Can't be too slow or too careful, especially when shaving into corners such as the area between the nose and cheek, or between the lower jaw and the front of the neck. Bald spots can happen in the blink of an eye!

I was also able to make better use of my mini-clippers this time around. They can't do diddly when the blade of the clippers is flat against the fur, it helped a lot to tilt them in a little bit, almost as if I were combing the fur with them, just going over the very tips very lightly. Much more control that way.
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 Daughter Isabelle gives Maxine a brush and comb after her shave and trim. Next up, airbrushing!

Some of the biggest improvements I hoped to make from my last head to this one involved sewing. Specifically, I wanted to see just how well I could get the fur to fit the resin head, and I knew that last time most of what got in the way were my noob sewing skills. Too much bulk, in the way of excessive seam allowances, between the fur and the resin base. My control of the sewing machine was not precise, my seams tended to wander a bit, so the seam allowances could not be trimmed as closely as they otherwise might be. It did not help that my seam allowances were cut unevenly out of the fabric to begin with. Watching Monoyasha in her tutorials whip the pieces out of the fabric with an art knife made me think *I* could whip the pieces out of the fabric with an art knife- um, no. My sewing teacher tactfully pointed out it would help a lot to cut the seam allowances evenly and carefully next time. I also invested in a shiny new pair of Gingher fabric scissors, and cut the fabric by carefully sliding the tips along under the pile while cutting, to avoid abruptly shearing off the ends of the fur. This made cutting a great deal more precise.

Another thing that helped a lot this time around- practice and experimentation. On scrap fur, before the good fur. Kinda obvious, but.... I pretty much sewed up an entire mask out of scrap fur before I moved on to the fur I actually wanted to use.

​Above, the muzzle and the cheek pieces, cut out of scrap fur. Left, the pins are laid across the hash marks that show where these pieces join together. That's  a pretty intense curve! I tried several times to sew it with the sewing machine but just could not get a seam anywhere near as precise as I wanted it to be.  Which, resulted in a seam allowance I could not trim closely, which in turn resulted in unwanted bulk between the fur and the base. Above right, the solution to this problem... hand stitching! Specifically, the blanket stitch. Precise control, just about no seam allowance to speak of. You can see just how sharply the two pieces curve when where they join together. 
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Above, half of the face sewn together out of scrap fur. The piece in left hand photo is machine sewn, the one in the right hand photo is hand sewn with the blanket stitch. You can see how much more  bulk there is in the machine sewn piece, especially at the juncture between the muzzle and the cheek and the inside corner of the eye. For someone at my skill level with a sewing machine it's just about impossible to get that corner's three seams to come together precisely.

​Of course, it takes a zillion times longer to sew by hand, but, that's what audiobooks and  NPR podcasts are for.
 

Above, scrap fur sewn by hand into the face of the mask. I'm happy with how well it's fitting.  Though I also can't help but think of this: 
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Next, hoods. I wasn't sure if I liked the way Max's hood looked or not. The Velcro closure over the zipper made the hood relatively easy to get on and off, but it added a noticeable ridge down the back. My sewing teacher suggested I try to find a softer Velcro with a better drape next time, something I haven't done yet. However I did find a bunch of zipper tutorials online and made not one, not two, but three hoods trying them out. Ultimately I used the method described in my good ol' Reader's Digest Complete Guide to Sewing.  Above, laying out a zipper on a seam that's been temporarily basted closed, while Ezzy delights in this fantastic new cat bed that miraculously materialized on my work bench.

 Ezzy loves it when I break out the faux fur totes.
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​He also loves to help with laying out the pattern. Above, you can see just how helpful he's being.
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​Above, after carefully considering the matter, Ezzy decides that that pattern piece should be ALL HIS!!

OK, now that we've gotten that out of our system, back to sewing. (That's my daughter Isabelle smirking at me.)
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I love patterning! Seems like alchemy, turning masking tape and magic markers on a resin base into lovely soft fur on a lifelike head! The tutorial on patterning at Dream Vision Creations is quite good, I didn't find any gaps in the info there I had to figure out how to fill in myself.
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​Above,starting the endeavor. The base is covered with a layer of plastic wrap and masking tape, the neck is filled out with plastic bags from the grocery store. Note to self- prior to patterning, save plastic shopping bags, don't be so efficient about bringing them to the recycling station at Price Chopper. This time around I wound up having to steal a big handful at the self-service checkout after buying a few token cans of tuna fish. 

​Above, the taping completed, and the markings/areas of different colors marked in with blue magic marker. I haven't decided what kind of tape I like best for patterning yet. Last time I used Duck Tape, which is tough and durable (and comes in lots of fun colors!) but very, very sticky and so a little tricky to work with. This time I used plain old Scotch brand masking tape, which is less durable and not quite sticky enough.

Above, pattern pieces labelled. Looks about as comprehensible as hieroglyphics. I won't get into what it all means here, as the DVC tutorial covers it well, but I will add this one comment- too many hashmarks to show how the pieces go back together are almost as bad as too few. After I had my fur pieces cut out and ready to be sewn together, I had a fair bit of trouble figuring out how the cheeks and eyebrows lined up with the top and back of the head. It didn't help that with so many hashmarks, forgetting to mark one or two in on the fur pieces was inevitable. Taking reference photos like these of the whole thing before it's cut apart can be a real lifesaver.

Above, the head after a visit from the resident OMG OCD!! department. This being my own resin head, and my first effort at making one, I was acutely aware of all its asymmetries, however small they might be. One question I had was how a pattern made on only one side of the head (standard practice as I understand) would fit on the other. So I traced out the pattern on tape covered aluminum foil and flipped it to cover the other side of the head. And yes, I concluded, doing the pattern on only one side of the head works just fine. If anything, doing this helps even out any of the head's little asymmetries.

One thing this exercise DID do was help show me which pieces could be flipped from one side to the other, thus making one big piece without a seam, and which pieces really did need to be two pieces, even if otherwise the fur was all the same color and all went in the same direction and such. For example, the big panel on the neck directly below the jaw looks like it could be one piece, saving me a seam up the middle, but I found there was no way to make one big piece out of it and accommodate the curve going from the center of the chest to the underside of the jaw. So two pieces it stayed. The little triangular shaped part under that piece, however, could  be flipped and made into one piece.
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Above, the pattern removed from the head, ready to be cut apart and used for a pattern. I think the masking tape "skin" is so cool. Next, laying out the pattern, cutting out the pieces and sewing!

My daughter loves Max and so do I, but...

​I want Maxine's (aka Head #2's) ears to be better than Max's. This is at the top of the list of improvements I want to make this time around. Not only is the fur going the wrong way on Max's ears, growing towards the base instead of towards the tip (in spite of the fact I *did* mark the fur direction correctly on the pattern!) but IMO the ears... flap around... too much when the mask moves. You can see this especially clearly at .018 minutes in this video.

Above, the nascent Max with his freshly designed Foamy ears. (And the cat hair mustache my daughter made for him.) I think part of the issue is evident here- the ears have too much height in relation to their width at the base. Theory being, a wider base would provide more support and hopefully, less flapping.

Above, snips from one of Dream Vision Creation's ear making tutorials (used with permission.) I referenced these often making the patterns for Maxine's ears. The ears on this mask are a bit wider at the base than are Max's. If they were his ears, the bottoms would come to the point where the top half of the hinge is glued to the head, not to nearly the center of the hinge as they do.

Above, using a snip from a Dream Vision Creations tutorial (left) as pattern reference for Maxine's ears (right), aiming for the correct width at the base.

.Above left, the paper pattern in progress, and right, the finished Foamy ears. Looks like I initially made the patterns a little bit **too** wide at the base, and so narrowed them down a bit in the final version.

Above left, the pattern piece (tan) for the back of Maxine's ears, and right, the pattern piece (green) for Max's. (See, I DID mark the proper fur direction on Max's pattern piece!!) As it turns out, both pattern pieces are 6 1/2" high, but while Max's pattern piece is 7" wide, Maxine's is nearly 9" wide. 

And since Maxine isn't finished yet, this is the closest thing I have to a side by side comparison of the two- Max is the green one and Maxine is the tan one. (Credit where credit is due- Max is made entirely with DVC parts, where Maxine is made with my own resin base and DVC nose, teeth, tongue and eye blanks.) So far I like the ears with the wider base much better! I think there'll be other things I'll need to do to prevent flapping, however... stay tuned!!

Moving jaw test for Maxine the Mask. Thank you to the long suffering hubby for his patience!!! I'm pretty happy with it.

​​I also wanted the teeth to sit up much higher in the lower jaw than they did in my first head, as they kinda disappeared into lips and fur after I got it assembled. I played a lot with layers of Foamies underneath the teeth to get them exactly where I wanted them, and so far I'm happy with how they look.

As with the previous head, I've been referring to the DVC tutorials online as I work on this head, and much to my confusion they've started redoing that series- when I did the first mask, the lips were applied last, after the airbrushing, and now they're applied early in the process, along with the eyelids. Maybe they were done last in the first series so that airbrush overspray wouldn't get on them, but that's easy enough to paint over with black paint. In any case it was a pain to apply them with fur already there, and so far I like this way better.
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​I also learned the hard way it's best to cut the cast up right before assembling it. I was so excited to get a good cast I couldn't wait to open the eyes up and hinge the jaw, and then I let the head sit, and sit, and sit.... and the jaw warped, shifting to one side. Now the head has an expression kinda like this: :-/ Nothing that can't be fixed with a Dremel and some epoxy, but still, something I'd rather avoid in the future.

Above, working out how to resculpt the jaw to make it look straighter. I often take a photo of an area I'm working on, print it out and draw on it, to help visualize what I should do. In the printout /drawing to the right, I've decided to dremel off the lip outside of the thick blue line. Another point for adding the lip early on- it gave me a way to tweak the jaw I wouldn't have had otherwise.

(And... one day I went down into the basement to work, and I found my daughter had gotten into my packing peanuts....)

Above, the lower jaw resculpted and straightened out a bit. I think it looks much better. Neatening up the edge of the lower lip helped a bit too.

Above, chiffon added to one tear duct but not yet the other, as modelled by my packing peanut loving daughter. Freaky deaky!

​Two takeaways for the next resin base sculpt:

First, make sure the areas in which the eyes will be glued are as flat as possible and in the exact same plane with each other. Any crookedness or unnevenness in these areas will be greatly exaggerated when the resin eyes are in place, and gives the mask a rather wall-eyed, inbred expression. Next base sculpt, I think I'll use metal or rigid plastic discs of the correct size to mark out these areas and leave them there while moldmaking, to make sure those areas don't squish out of shape. I was able to glue the eyes into this base to my satisfaction using bits of resin and hot glue to level them out, but care taken with the next sculpt could definitely make the process a lot easier. 

Second, sculpt the next head so that it can easily take a nose with a flat back. DVC noses, and I suspect any other noses that are cast separately and glued on to a base later, have flat backs. I suspect they are made in one piece molds, the backs of which are open so that the casting material can be poured in, which then levels out as it sets. When I removed the nose on this base to accommodate the DVC nose, I was left with an awkwardly shaped hole into which to glue it. I re-sculpted the area a bit with epoxy so that the nose would fit (the thick black band behind the nose in the pics is epoxy for the most part) and so all is well that ends well, but again, this is something to take into consideration for future head sculpts.

Next, ears!!

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