Wookiee mask build.

Start your Fringe WIPS here

Moderator: DCO

User avatar
Larphitupfuzzball
Costume Specialist: Chewbacca
Posts: 346
Joined: Wed Jan 03, 2018 1:59 pm
Name: Paul Smith
2020 Troops:: 3
Total Troops: 107

Wookiee mask build.

Post by Larphitupfuzzball » Mon Mar 02, 2020 7:04 pm

Thought I’d put this WIP together for any prospective Wookiee builders.

Generally if your going to build a Wookiee, you’ve got three options when I comes to the mask.

1. Commission a complete mask from one of the expert builders such as Chewbacca 5.2, EvilChimp FX or Paul Humphries. The benefit of this is you’re going to get a cracking mask from someone with loads of experience. The downside is they’re not cheap and depending on orders you could be waiting a while.

2. Purchase a mask kit and build it yourself. The pro’s of this is it will save you a bit a cash, the satisfaction that you built it and the enjoyment of the actual build process. There aren’t really any downside although it may take a while to achieve the quality of those expert builders.

3. Build it from scratch. There’s a lot more involved with this as you have to create a cast for your underskull, create a cast for you mask/face out of clay etc. Generally if your going down this route then you’d be looking to start offering your own kits to recoup the effort.

So for the purpose of this wip we’re looking at option 2. I purchased my kit from Paul Humphries and it consists of the fibreglass underskull, latex mask, teeth and tongue. I made a few Wookiee mistakes but got there in the end.

Image
Last edited by Larphitupfuzzball on Mon Mar 02, 2020 9:02 pm, edited 2 times in total.

User avatar
Larphitupfuzzball
Costume Specialist: Chewbacca
Posts: 346
Joined: Wed Jan 03, 2018 1:59 pm
Name: Paul Smith
2020 Troops:: 3
Total Troops: 107

Re: Wookiee mask build.

Post by Larphitupfuzzball » Mon Mar 02, 2020 7:11 pm

The 1st step was to assemble the mouth. My teeth arrived unpainted so I painted the gums with some Tamiya acrylic red paint I had lying about and left this to dry.

Image

Next once dry, the silicone sealant was applied around the edge of the teeth and this was attached to the tongue and clamped together with light pressure and left to cure for 24 hrs.

Image
Image
Image
Last edited by Larphitupfuzzball on Mon Mar 02, 2020 7:18 pm, edited 1 time in total.

User avatar
Larphitupfuzzball
Costume Specialist: Chewbacca
Posts: 346
Joined: Wed Jan 03, 2018 1:59 pm
Name: Paul Smith
2020 Troops:: 3
Total Troops: 107

Re: Wookiee mask build.

Post by Larphitupfuzzball » Mon Mar 02, 2020 7:18 pm

Next step was to attach the strapping to the underskull. A safety visor purchased from Selco builders merchants was used and trimmed to size. The attachment points were marked on the underskull and slots cut using a Dremel

Image

Next the tabs were placed through the slots and checked for comfort, once happy with everything the tabs were secured in place using paper fasteners and covered with padding.

Image
Image

Padding was then added to the inside of the underskull and strapping

Image
Last edited by Larphitupfuzzball on Mon Mar 02, 2020 9:04 pm, edited 1 time in total.

User avatar
Larphitupfuzzball
Costume Specialist: Chewbacca
Posts: 346
Joined: Wed Jan 03, 2018 1:59 pm
Name: Paul Smith
2020 Troops:: 3
Total Troops: 107

Re: Wookiee mask build.

Post by Larphitupfuzzball » Mon Mar 02, 2020 7:21 pm

With the teeth now cured these were attached to the underskull using araldite. The position of the teeth were marked on the underskull to ensure alignment and left to harden

Image
Image

Padding was added to the bottom of the underskull to allow operation of the jaw once the araldite had hardened.

Image

User avatar
Larphitupfuzzball
Costume Specialist: Chewbacca
Posts: 346
Joined: Wed Jan 03, 2018 1:59 pm
Name: Paul Smith
2020 Troops:: 3
Total Troops: 107

Re: Wookiee mask build.

Post by Larphitupfuzzball » Mon Mar 02, 2020 7:26 pm

Attention then turned to the mask itself. The alignment was checked with the slot cut in mouth

Image

Silicone was then applied to the underskull

Image

And the mask placed on the underskull and allowed to cure for 24hrs

User avatar
Larphitupfuzzball
Costume Specialist: Chewbacca
Posts: 346
Joined: Wed Jan 03, 2018 1:59 pm
Name: Paul Smith
2020 Troops:: 3
Total Troops: 107

Re: Wookiee mask build.

Post by Larphitupfuzzball » Mon Mar 02, 2020 7:28 pm

A template was created for the mesh cowl

Image

And sewn together

Image

User avatar
Larphitupfuzzball
Costume Specialist: Chewbacca
Posts: 346
Joined: Wed Jan 03, 2018 1:59 pm
Name: Paul Smith
2020 Troops:: 3
Total Troops: 107

Re: Wookiee mask build.

Post by Larphitupfuzzball » Mon Mar 02, 2020 7:29 pm

With the mask now bonded to the underskull the eye holes were cut before applying 3 coats of liquid latex to the edges

Image

User avatar
Larphitupfuzzball
Costume Specialist: Chewbacca
Posts: 346
Joined: Wed Jan 03, 2018 1:59 pm
Name: Paul Smith
2020 Troops:: 3
Total Troops: 107

Re: Wookiee mask build.

Post by Larphitupfuzzball » Mon Mar 02, 2020 7:31 pm

Next the cowl was attached to the underskull by bonding with the silicone between the edge of the mask and underskull.

Image

User avatar
Larphitupfuzzball
Costume Specialist: Chewbacca
Posts: 346
Joined: Wed Jan 03, 2018 1:59 pm
Name: Paul Smith
2020 Troops:: 3
Total Troops: 107

Re: Wookiee mask build.

Post by Larphitupfuzzball » Mon Mar 02, 2020 7:32 pm

A few ours of latching the hair to the cowl and we have this.

Image
Image

User avatar
Larphitupfuzzball
Costume Specialist: Chewbacca
Posts: 346
Joined: Wed Jan 03, 2018 1:59 pm
Name: Paul Smith
2020 Troops:: 3
Total Troops: 107

Re: Wookiee mask build.

Post by Larphitupfuzzball » Mon Mar 02, 2020 7:35 pm

Now for the hard part. Hair was bonded to the mask by using the silicone sealant and a spatula, building up the layers as you go. Started with the grey and then moved onto the blonde / brown.

Image
Image
Image

User avatar
Larphitupfuzzball
Costume Specialist: Chewbacca
Posts: 346
Joined: Wed Jan 03, 2018 1:59 pm
Name: Paul Smith
2020 Troops:: 3
Total Troops: 107

Re: Wookiee mask build.

Post by Larphitupfuzzball » Mon Mar 02, 2020 7:39 pm

After quite a few hours we ended up with this.

Image

It’s certainly not going to worry any of the builders mentioned at that start of this WIP but I have to be happy with the outcome. It still needs a bit of hair punching and tweaking but I does look better in person and it is by far the most comfortable of all the masks I own.

User avatar
WookieeDave
Posts: 77
Joined: Fri Jun 01, 2018 9:16 pm
Name: David White
2020 Troops:: 1
Total Troops: 5

Re: Wookiee mask build.

Post by WookieeDave » Tue Mar 03, 2020 6:52 am

I can't see any photos mate

Sent from my HRY-LX1T using Tapatalk


User avatar
Larphitupfuzzball
Costume Specialist: Chewbacca
Posts: 346
Joined: Wed Jan 03, 2018 1:59 pm
Name: Paul Smith
2020 Troops:: 3
Total Troops: 107

Re: Wookiee mask build.

Post by Larphitupfuzzball » Tue Mar 03, 2020 7:45 am

I have issues hosting the photos so Alex is going to add them for me. I’ll post up an update when they’re added mate.

User avatar
Larphitupfuzzball
Costume Specialist: Chewbacca
Posts: 346
Joined: Wed Jan 03, 2018 1:59 pm
Name: Paul Smith
2020 Troops:: 3
Total Troops: 107

Re: Wookiee mask build.

Post by Larphitupfuzzball » Tue Mar 03, 2020 2:59 pm

WookieeDave wrote:
Tue Mar 03, 2020 6:52 am
I can't see any photos mate

Sent from my HRY-LX1T using Tapatalk
Pics now added. Hope you like it.

User avatar
Jerrick Sunrunner
Elstree Base Base Commanding Officer Krayt Squadron CO Southern Events Coordinator
Posts: 2601
Joined: Tue Jan 02, 2018 6:58 pm
Name: Mark Mulcaster
Location: North Knebworth Hertfordshire
2020 Troops:: 0
Total Troops: 54
501st Number: BH63827
MMCC Name:: Jerrick Sunrunner
Contact:

Re: Wookiee mask build.

Post by Jerrick Sunrunner » Fri Mar 06, 2020 10:58 am


Thanks for the guide Paul, that’s really insightful :)
Elstree Base Commanding Officer (BCO)
1138th Krayt Squadron Co
London & South East Events Coordinator
Rebel Legion Pilot Costume Judge

Post Reply

Return to “Fringe Work in Progress”