I'm making a surfboard that is actually fairly similar to that (a bit more round at the top and the fat part moved up towards the top a bit). Anywho, what did you use to make yours? I cut mine out of word and I used too soft of wood so I think I'll have to redo it. Looks like you might have used Aves. Just curious because it looks rather uniform.

For the surfboard I made a template out of plastic. I put the aves apoxie sculpt on top of that in a thin layer on each side. It did start to delaminate during the sanding process but a bit of super glue fixed that. It was A LOT of sanding to get it smooth. To see my low spots I would spray it with primer them sand it down. Some low spots I had to fill with more clay and some I let the prmer build up in. I must have sprayed and sanded the whole board 5 times so far. I should probably go over it one more time but I don't think I will.

Thanks for the tip! Edstuff also recommended possibly using bondo. I'll be exploring that over the weekend.

bondo would work. Its easier to find and you could get it today. Just make a shape out of something first. Bondo one side, shape it, let it finish drying then bondo the other side.

UPDATE:

Made mold boxes for all the parts. I should have my brushable silicone coming today for the body and resin for slush casting. Hopefully I can get the first unit pulled for Thursday! Its about a 25 piece toy with all the accessories. I will take some process pics tonight.

Awesome, can't wait.

Here are some process mold images.

Ah, the mustache is too awesome. Are they one offs or you making a bunch?

The professor was an earlier sculpt. I had some extra silicone that I didn't want to waste so I set it up to mold. I don't know how a glove mold will work with his mustache but I would rather experiment with a hand turned rotocast than a solid fill resin piece. And he is going to use the universal monster feet.

I forgot to buy the thickener for the glove molds on the surf board monster and professor. Instead of being done with them right now I will need to go back and recoat them again a couple more times and hope the silicone bonds to itself.

I cast the eyeball. Worked out nicely. Arms - not so much. The recess for the joints had some deep undercuts. I think I will have to engineer a 3 part mold to make them work correctly.

Really looking forward to seeing these done

This has been fascinating to watch and read through. Thanks for posting all your progress, it's been great to see your procress, and progress.

Some great sculpts here, really like your work.

Should be able to finish my molds tonight. Redoing the arms and finishing the glove mold on the body. I just might be able to get test pulls on everything next week.

Any chance for a little shopping list of the materials you've used for casting? The whole process seems way too difficult for me to want to take on.

Sculped from a tinfoil base wrapped in Apoxie Sculpt - 2 part epoxy clay
Sanded with 200 grit
Oilbase clay created the base of the 2 part mold.
hot glue
Foamcore board or cardboard (cardboard sucks by the way but it was handy
2 part silicone plus thickner - Polytek
120 resin for slush casting of body - Polytek
other resin for arms feet and eyes - Dascar Plastics
2 part silicone for 2 part molds - hobbysilicone.com

metal tools for sculpting - Harbor freight
wood tools for sculpting - hobby lobby

Bushings for joints - Lowes
Dowels for joints and mold boxes - Lowes