The process is simple in concept but tedious and painful in application. Here you can see poor Tank trying out the bicycle seat he'll be sitting on for an hour covered in plaster. Not to mention the poor guy had to shave....all over. We're getting to that....
Alright, what fallows are a few pictures of the bandaging process. What you'll see is bandages being applied to the front, and then a flange created which will be wiped with petroleum jelly. Then the back plate of bandages will be made right on top of that so that the two pieces are separate. Sticks are put in the places along the arms and legs that will have the most resistance between them when the cast is pulled off.
That black line is the flange, that way the two pieces can be removed. We're using hot water and straight up plaster bandages, which is why you have to shave, otherwise it'll pull your hair out.
The feet are elevated up to fit inside of the legs of the costume, the ogre is going to have around a half a foot or more of foam under that actor's feet, giving the costume greater height than a normal human. Your feet have to be hidden in the leg above the foot, and hence at more of an angle. Like high heels, but scary. Here's a little example I drew up with a piece of concept art that is amazing, and not drawn by me except the red parts and where I drew a snap line on the head...
It might not have taken so many people, but no one can resist a party.
The finished cast! After being pulled off gingerly and Tank was allowed to be free and have a smoke. It only took about two hours. Not bad, right?!
Anyway, now next comes the final fiberglass mold of the body cast, and the head cast! But we ran out of bandages. So until next time...I'll be updating at least weekly, it's only 6 months until comic con and I have around 5 costumes to make. SO keep watching!!