Alright, here's another one of those processes I'm going to sort of muddle over. It's not that it wouldn't be fascinating, but it's one of those things that despite pages of blogging, it'll still be really hard to do if you try it. But, I do have pictures! We poured the foam latex test head at work the other day, using work's giant mixer and syringe. It came out with a few bubbles, but it's a test skin, so it's fine.
This is GM prosthetics grade foam latex, rather than animatronic grade which is a little more dense (and mrroe expensive, eeeew) Since this will be animatronic, it'll take a little beating, but it's not going to be any serious business metal parts, it'll mostly be fiberglass and plastic. Here's a pic of the head! it sort of feels like moist bread and smells like rotten pastries:
Now I have to do some more things to this test skin, including cut it in half, fiberglass the inside, make a head cap thing, etc etc, all so it can be worn as a real costume piece! But right now, I need to finish the N7 armor before the 22nd. Wish me luck...I'll be updating!