How to Make a Character Using Fiberglass Over Foam
- 1). Create your character using a series of photos taken of the character model from all sides or a series of drawings from multiple angles. Mark an outline of your character using a marker on the sides and top of a foam block large enough for the character sculpture. Shape the foam by cutting away sections with a hobby knife or serrated kitchen knife to get a rough shape of the character. Shave away smaller portions of the foam using a wood rasp and sandpaper to provide details. You can also alter the shape of the foam by compressing sections with the pads of your fingers to the desired shape.
- 2). Hollow out the eye sockets and mouth of the head of your character with a hobby knife for the placement of manufactured eyes and false teeth if you desire a realistic look for your character. Sand the sides of the hollows smooth with fine-grit sandpaper.
- 3). Sand the rest of the foam character smooth with fine-grit sandpaper and then wipe the surface with a clean cloth to remove any sanding residue.
- 4). Mix the two-part resin in a plastic cup using a wooden stir stick according to the manufacturer's instructed mixing ratio. Brush the resin onto the character using a paintbrush in a thin layer. Allow the resin to dry slightly until it's tacky but no longer appears wet.
- 5). Place the fiberglass cloth over the resin, cutting the cloth into strips with scissors so that it fits smoothly over the character, with a slight 1/2-inch overlap where pieces meet. Brush a layer of resin over the cloth to fill in the pores and help adhere the cloth in place. Allow the resin to dry overnight.
- 6). Sand the overlapping edges of the fiberglass smooth with a fine-grit sandpaper, removing all signs of the overlapped lines.
- 7). Spray the character with a primer to prepare the surface for painting. Allow the primer to dry completely before painting the character with the colors of your choice.