help-materials for a disneyland like head?

[tysiony]

Hi guys

Been asked by a client to create a disneyland like head of two characters we have animated for them-we started off with discussions about paper mache like frank sidebottom http://www.franksidebottom.co.uk/
But its not as smooth as they'd like.I've discussed latex and muppet/puppet heads but they're not as keen on that either.
Would I be able to use resin -do the front half and back half and somehow stick them together? Would it even be safe for people to wear?
I've tried researching disneyland heads in various ways on google to see how they are made but no luck.I'm assuming them are some sort of plastic and I may not be able to do the job fullstop.Any advice appreciated!

[Emphantasy]

I did some big walk around costume heads for Enesco years back- the only way I could make them light enough was to vacuum form a front and back half, glue together, and then paint- worked pretty well.

[tysiony]

Thanks I did think that might be the way to do it!- what paint did you use?

[Emphantasy]

If I remember right, it was probably cans of spray paint - it was for a "Precious Moments" character, so everything was pastel, and easy to find off the shelf... I did a light washing, then sanding with very fine (they were pulled out of styrene) just to rough the surface a little for the paint. The hardest thing was to get the halves to attach, as it was pretty thin styrene, but once I added a strip to the inside of the front of the head, it created a "tongue" that the back of the head slid onto. I think I used pop rivets to hold it all together- surprisingly strong once it was a whole "sphere" (completed head). I can post pics later tonight after I get home, if you'd like.

[tysiony]

would you ? that would be great! Thanks!

[Emphantasy]

Here are some of the only pics I have. You can see a little of the seam at the bottom edge, which was padded as it rested on the wearer's shoulders. The eyes were black screen, allowing the wearer to see out.

[Cissell]

Creepy precious moments head!

[tysiony]

Thats great thanks Emphantasy