Materials And Introduction
There are many tools and techniques used in creating a full body costume. In this exercise I will be using the materials and techniques that I have found to work best for me. Over time I have learned that what works for one person may not work for others, so I will also try to include other methods and substitute materials. The materials necessary to complete each Phase of the project will be listed at the beginning of each section.Warning: Some of the materials in this website may be harmful if improperly used. Always carefully read your instructions, and product warning labels before you begin. Always wear protective gloves, clothing, respirators and eye protection when necessary. I claim no responsibility for anyone's injury or ignorance. I do not endorse any of the materials used in this site. (unless one wants to sponsor me)
Materials Phase 1-
There are several different ways to make a body casting. Most prefer to use plaster bandages for the casting, which has its advantages, its easy to use, and its not too messy. However it can be rather costly. In these Demos I will also show how one can cut costs wherever possible. For this casting I will be making my own plaster bandages.
Burlap- This will be used as the bandage for the plaster. You can purchase large quantities of burlap from most fabric supply stores. For this entire costume project I used about 6 to 8 yards total. You will want to pre-cut the burlap into various sized pieces. (the sizes I like to use are large- about 16x6, medium- 10x6, small- 6x3)
Ultra-Cal 30- A high grade gypsum cement. This will be used as the plaster for the bandages. You can find this at most pottery supply stores. On this cast I used about 3/4 of a bag or about 75lbs. The quantity you will need depends on how thick you will be making your casting. I recommend you get al least 200lbs. to start off. (its better to have too much then not enough, and you will need more Ultra-Cal for later steps in the project)
Plastic Wrap- This item will be used as the release agent. I find that the cheaper the plastic wrap the better it seems to work. You can get this at any grocery store. One large roll should be more than enough. (you may also use the Vaseline technique, which requires the model wear a full length Spandex leotard, or similar tight fitting garment. Then lots of Vaseline is smeared all over the model.
Wooden Support Strips- These will be used to reinforce the mold. These should be measured and cut to match your models dimensions before you begin.
Vaseline- This will be used as a release agent for the seam on the plaster bandages. You will need at least 2 large jars. This item will also be needed at a later stage. Be sure to use some to cover any exposed fleshy areas that the plastic does not cover, like hands and feet.
Mixing Bowl/Buckets- You will also need a mixing container for the plaster. The ideal mixing container would be a large rubber bowl, thus when your plaster sets you just pop it out and your ready for your next mix. However I once again chose the Cheap-Ass route, using a couple of 5-gallon buckets.
Assistants/Helpers- You probably wont be able to do a body cast by yourself. I managed to do this stage with the help of only one assistant. The casting will go easier and quicker with more people. (I recommend at least two assistants)
