Staff Progress

I have been blazing right along with the construction on this project.

Yesterday I left off with filling in air bubbles.

The next step is to decide the length of each segment. I am flying out to Blizzcon, so my props and costumes need to fit into my luggage. The standard for carry-on luggage is 45 linear inches, and I know my suitcase is 21 inches in length, so each section is approximately 20 inches without hardware.

Once everything has been measured I cut and sand the edges, then drill pilot holes for my bolt hangers and insert nuts. These will be used to attach the sections into one whole, sturdy piece.

After the hardware is installed, I glue cardboard platforms onto the ends to keep foam from covering my connectors. I cut these into the desired shape, they are useful as a guide while carving as well as a way to keep your hardware from getting covered with foam.

The next step is to paper-mache over the foam base. I used brown butcher paper torn into strips with 3/4 cup flour and about 1 cup water for the paste. Be sure to only do one layer at a time, and try not to have too much overlap. You must let each layer dry completely before moving on to the next, or your project will risk molding and becoming ruined.

I am still in the process of adding layers of paper-mache. It is a slow process, I recommend putting a movie on or listening to a sweet playlist while you work!