- Material selection -
Select the materials you will need for the project. For this project I chose to go with a foam core, a Plastalina (non hardening clay) layer for making the 3-D model, Flexwax for mold, and cast in latex with a foam insulation core.

 
 
 
 
 
 

The tools will differ depending on what materials you are using. Here are the tools I used callapiers for transfering mesurements clay working tools, a electric knife (from thrift mart) and a wonder cutter for the foam.


Bill of materials
Material:
Cost:
Explanation:
3/4" x 2' x 4' sheet foam
60 cents
for model core
Plastalina 5lb block
2lb-$6,5lb-$12.99
less is needed but better to be safe
Flex-wax 120 - 2.5lb block
$14
less needed but safe again
Mask making latex
varies by volume (small amounts@$9 for 16ounces)
for the latex skin
Great Stuff
$2.50 a can
For cast fill
3/4" pvc pipe 6" needed
10' for 99 cents
For attachment to body
Tools:
Cost:
Use:
electric carving knife
$1.75 (thrift mart)
cutting foam
Wonder cutter (hot wire cutter)
$1 (clearance at walmart)
cutting & working foam
Clay working tools
free home made
working plastalina
Calipers
$4
transfering measurements
Turntable
50 cents (home made)
aids in modeling head

* Note: cost is actually lower than shown because many of the materials can be reused this would show   the start up cost. Also the project can be done with less tools etc depending on how accurate & detailed you want the finished piece. While I used "flexwax" for the molding plaster could also have been used.