Scott Holden's Tauntaun Costume

Completely siliconed head.

Covered with plastic. The beginnings of the "mother mold".

Building a shell of expanded foam around the silicone.

Then I made a "mother mold" out of MDF and can-foam to hold the molds shape. 



The silicone mold.

After spraying a mold release agent into the silicone mold, two-part expanding foam was poured into the mold to create a replica cast.

A similar process was used to cast the horns.

The complete foam head.











Please continue reading page 3 of Scott's tauntaun costume.

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More on the Zone Ball costume contest | Q&A with Scott on the tauntaun costume | How to make a cheap silicone mold with ordinary silcone caulk | Greg's Bumblebee Transformer Costume

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