![](https://s3images.coroflot.com/user_files/individual_files/261365_jtmgww8yroes0wr7zfz_zgawm.jpeg)
Original bronze for reference
![](https://s3images.coroflot.com/user_files/individual_files/261365_ro85qb9nlyba3z60zpjzg0pvi.jpg)
quick clay study
![](https://s3images.coroflot.com/user_files/individual_files/261365_piykilrdwoitbfo7ileolykuy.jpg)
Welded steel frame supports the main structure of 2" foam blocks
![](https://s3images.coroflot.com/user_files/individual_files/261365_otnvlusmfqsbferi3veldfsz0.jpg)
![](https://s3images.coroflot.com/user_files/individual_files/261365_vnu_77tpho66bqazvqs4hbana.jpg)
Carving using reciprocating saws and hand tools begins.
![](https://s3images.coroflot.com/user_files/individual_files/261365_oo8dj_qlcf_hou0rnidavrmnb.jpg)
![](https://s3images.coroflot.com/user_files/individual_files/261365_ovk03valj9ezzhg95mfemmhrq.jpg)
![](https://s3images.coroflot.com/user_files/individual_files/261365_5tulcls7vczask94vcpkqezqn.jpg)
![](https://s3images.coroflot.com/user_files/individual_files/261365_x22ujez5zkn2knfmjibarbuwi.jpg)
![](https://s3images.coroflot.com/user_files/individual_files/261365_a62hz9rkdiopyb6nqd2pzvw4o.jpg)
The hair was sculpted quickly using an electric hot-knife to melt and gouge the foam.
![](https://s3images.coroflot.com/user_files/individual_files/261365_pxgduszr5n47no3la8_fvtaf_.jpg)
After a coat of black paint to help resolve the form, it is then coated several times with a clear epoxy-based hard coat mixed with polyurethan fiber for strength, giving it a very tough and scratch-resistant shell.
![](https://s3images.coroflot.com/user_files/individual_files/261365_n9smh8vfho_o5wvgalw4kyji2.jpg)
![](https://s3images.coroflot.com/user_files/individual_files/261365_sarektcvqmigej4snoxcoviaa.jpg)
The face was constructed out of harder density polyurethane modeling foam, then carved using a handheld rotary tool (approx. 30 hours carving time)
![](https://s3images.coroflot.com/user_files/individual_files/261365_xy977eu6h04wfqv99hygaq9yw.jpg)
![](https://s3images.coroflot.com/user_files/individual_files/261365_hvh8xzthwftgee3tqptdfhble.jpg)
Finally, the paint can be applied.
![](https://s3images.coroflot.com/user_files/individual_files/261365_tyzmxo2wqizwmc9gqpov48p5j.jpg)
![](https://s3images.coroflot.com/user_files/individual_files/261365_akr4qcctgbnuiupedyngxwxot.jpg)
![](https://s3images.coroflot.com/user_files/individual_files/261365_vkjuqxqdppsp3rjtgyu8gis9z.jpg)
![](https://s3images.coroflot.com/user_files/individual_files/261365_eslhz2eurp6ddrzopjkrizsgm.jpg)
![](https://s3images.coroflot.com/user_files/individual_files/261365_4cas7lhokrtduykbllvvmffx_.jpg)
Foam mold pattern for a large "icicle" structure to be cast in clear resin. This detail was ultimately scrapped due to time and budget constraints. (Spray-painted green for form clarity)
![](https://s3images.coroflot.com/user_files/individual_files/261365_ewjh3y3cbn8nqtgtluj3y5ycd.jpg)
Silicone applied to mold pattern
![](https://s3images.coroflot.com/user_files/individual_files/261365_ikozqqjmphsnmzruyvvf_lzlx.jpg)
Mold construction begins
![](https://s3images.coroflot.com/user_files/individual_files/261365_qsqrqc_x9f0gl75guwoibmca_.jpg)
Finished mold with pattern
gLike