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Many questions on resin/silicone casting/random (beware lots of text..)

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Hello again! This community is always very helpful so I'm hoping I can get some advice here. I want to get into resin cast masks and I've done a lot of research through memories, youtube, etc. but I've come up with some questions. I hope these are not repeats...



I have always wanted to try the resin mask method but couldn't think of what sort of character to do. Then it hit me and I decided on a partial of Amaterasu from the game Okami (I know...everyone's done it but I still want to try!) Here's my roughly doodled ref:



The questions I have revolve around the resin and silicone materials I want to use so I will briefly explain my ideas:

The head ofcourse I want to be resin. I've researched extensively on that process and plan on using Rebound and Smooth cast 65D from Smooth-On.com (helpful site btw)

I also wanted to think of how to make her shield/mirror so it isn't...flimsy...easily breakable, so I thought, why not cast that out of resin too. So I planned on just investing in a gallon of the smoothcast and using that for both the shield and mask. I plan on using that for more things in the future so as not to waste it.

For the mold of the shield is where my issue comes as to what silicone to use. I plan it to be an easy one piece mold that you just poor in the resin making the back of the shield completely flat. I looked at just about every every silicone product smooth on offers as well as read what people like to use here. Since I am going to also need a gallon unit of silicone for the shield mold (and I also plan on making noses, paw pads, etc. with it as well) I'd like to have a type that can be used for both the mold and those pieces so as to not waste the rest and save some money. I wanted to be able to add pigment to it as well, so that rules out some of them as they're better for just making molds and aren't translucent. I read a lot on their website and thought maybe the Ecoflex series may work for me. I had thought this because I do not own a vacuum chamber and really don't have the money to invest in one right now (nor do I do this often to warrant one) and they claim that silicone has a lower viscosity and prone to less bubbles...So I ordered some samples and really didn't like them....they were just way too squishy imo. Smooth On was also kind enough to include a couple samples of Dragonskin which I instantly loved much better. So I'm really leaning towards that.

So, after that wall of text, my questions are as follows:

1) (kind of off topic) what kind/size computer fans do you fit inside resin masks since their noses are so small? Where do you usually get them? Also, how do you attach them inside to the resin?

2) (off topic again) I plan on the top of the leg sleeves to have elastic to keep them to stay. How is the elastic sewn in? Is there really anything special about that or just sandwhich together and sew?

3) I've heard of many people using Dragonskin which I read really works best using a vacuum chamber. Do you NEED to have a vacuum chamber? Is it a waste of money for me to even try this without one?

4) (part of above question) I read on Smooth On that if you don't have a vacuum chamber, you can first paint on a thin layer on your object and then poor on the rest afterwards to avoid bubbles. They also did this on one of their videos. Has anyone tried this? Do you think that would be sufficient?

5)If I plan on casting the whole shield of resin, do you think that would be heavy? I have a sample disc of the resin too and it seemed pretty light.

6) Overall, what are you opinions on how I'm [currently] planning on doing this? Any better ideas?

7) Would the plaster bandages/plaster of Paris work for making the hard mold that holds the silicone together for the mask?

Also, I'm definitely aware I need to use sulfur free clay and the safety requirements necessary to use these products. I have a respirator and arrangements to use a well ventilated area. This isn't something I just thought of on the fly to try. XD

Any help would be greatly appreciated!

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