While Oscar-nominated special effects character creator Alec Gillis (Aliens, AvP, Tremors) is definitely the captain of the ship, the process of making a complete monster suit takes an entire crew. See how the cooperating efforts of the Amalgamated Dynamics, Inc. special character effects team come together to create a unique creature that, by the end of the lesson, is worn and brought to life by one of Hollywood's top monster suit performers, Oscar winner Tom Woodruff, Jr.

This DVD is a 2-Disc Set

Advanced Level

4h 4m of duration

English (auto), Spanish (auto)

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Curriculum

1. Title & Introduction - 54s

2. Prepping the Head Sculpture for a Mold Jacket - 2min

3. Smoothing Out the Clay Jacket - 1min

4. Clay Keys - 3min

5. Aluminum Keys for the Fiberglass Case - 3min

6. Applying Release: Crystal Clear and Wax - 2min

7. Applying Bondo Resin - 2min

8. Applying the Fiberglass - 4min

9. Prepping the Fiberglass Case for Pouring Silicone - 4min

10. Releasing & Closing the Fiberglass Case - 4min

11. Measuring Silicone - 3min

12. Catalyzing the Silicone - 2min

13. Pouring the Head Mold - 3min

14. Demolding the Head - 3min

15. Laying Up the Resin Core - 4min

16. Resin Coating the Head - 4min

17. Demolding the Resin Head Core & Prepping for Foam Latex - 2min

18. Seaming & Patching the Resin Head Core - 1min

19. Creating an Alginate Test Skin for the Head - 1min

20. Demolding the Test Skin for the Head - 27s

21. Determining Skin Thickness for Animatronics - 3min

22. Brush-up Mold – A Negative Mold of the Core - 5min

23. Opening the Mold - 2min

24. Components of the Creature Head - 8min

25. Vacuform - 6min

26. Test Fitting the Skin - 5min

27. Test Mounting the Skullcap to the Core - 5min

28. Readjusting the Roll Axis - 4min

29. Test Mounting on the Actor - 5min

30. Conceptual Mechanics of Expression – Planning How to Move the Face - 17min

31. A Tale of Two Cores – Stunt Head and Animatronic Head - 1min

32. Establishing & Locating Animatronics - 2min

33. Vacuforming the Core as a Registration Tool for Mechanics - 3min

34. Making the Latex Hero Skin - 2min

35. Mixing the Foam Latex - 3min

36. Injecting the Foam Latex - 4min

37. Building the Body Mold - 5min

38. Surface Layer - 3min

39. Applying the Fiberglass Resin - 2min

40. The Foam Latex Body Suit - 1min

41. Injecting the Body Mold with Foam - 53s

42. Baking the Foam - 2min

43. Demolding the Body Suit - 2min

44. Prepping the Suit for a Test Fit - 3min

45. Test Fitting the Suit - 11min

46. Sewing the Suit - 1min

47. Seaming & Patching the Suit - 4min

48. Painting the Suit - 45s

49. Materials - 2min

50. Painting the Body - 9min

51. Base Coat - 2min

52. Painting the Body - 3min

53. Washes - 3min

54. Airbrushing the Palms of the Hands - 2min

55. Secondary Washes - 3min

56. Dry Brushing Clay Texture - 5min

57. Adding a Dark Top Wash - 2min

58. Adding Color Detail - 5min

59. Costume Elements - 2min

60. Sealing the Body Suit - 2min

61. Painting the Head - 47s

62. Painting the Head - 5min

63. Painting the Head - 2min

64. Painting the Head - 2min

65. Painting the Head - 5min

66. Painting the Head – Character Design Elements - 2min

67. Painting the Head - 3min

68. Painting the Eyes - 4min

69. Airbrushing the Iris - 3min

70. Details in the Iris - 5min

71. Airbrushing the Sclera - 3min

72. Applying a Coat of Crystal Clear - 3min

73. Fitting and Testing the Eyes - 2min

74. Wrap Up - 3min

Materials

CLICK on the links below to find the materials you need for this lesson.

Some items might be harder to find, but a little internet scouring usually finds you everything you'll need.

Mouldlife USA

Mouldlife Europe

Naimie's Beauty Center

McMaster Carr

Reynolds Advanced Materials

Smooth-On Inc.

GreatArt UK

FOR YOUR WORK STATION

Acrylic spheres 2x for the eyes (Precision Ball in IL)

C-Clamps

Evacuator

Latex Gloves

Mix Master Mixers

Organic Vapor Mask

Oven

Vacuform Machine

AIRBRUSHES

Airbrush

CLAYS/PLASTERS

Alginate

Hydrocal Plaster

Plaster Bandages

Ultracal

Wed Clay

CLEAR COATS/GLOSSES/MATTING AGENTS

77 Spray Cement

Bulls Eye Shellac (Amber)

Crystal Clear Acrylic spray

EPOXYS/GLUES

Epoxy Putty

Epoxy Resin

FABRICS

Burlap or Sisal Fiber

Fiberglass fabric

Fiberglass mat

Nylon stocking material

LATEX/SILICONE

Foaming Agent (GM Foam Inc.)

Latex Base

Silicone (around 8000-10,000 grams) + green catalyst

PAINT/BRISTLE BRUSHES

Detail Paint Brushes

PAINTS

Acrylic paints (white and grey)

Proline Tints

Rubber Cement Paint+Oil paint mixture

Vmatte

PLASTICS

20,000 PEG plastic

Sheet of 0.030 PTG thermal plastic

RELEASES

310S Mold Release Spray

Baby Powder

Blue Mold Wax

Castor Oil

Partall Film #10

Vaseline

RESINS

Black Gel Goat with Catalyst

Bondo Resin

Bondo

Laminating Resin

Cream Hardener for the Bondo Resin

Catalyst for the laminating resin

Polyester Resin “Mud” (Polyester Resin Thickened with Cabosil)

Polyester Resin with MEKP Catalyst

Laminating Resin with Black Tint and Cabosil added

SPONGES/POWDER PUFFS

Scott Foam Black

Poly Foam Upholstery Foam

THICKENING AGENTS

Cabisol (Thickener to silicone)

Gel component (solidifies foam latex mix)

THINNERS/SOLVENTS

Acetone

Denatured Alcohol

TOOLS

Bits and Indexes

3/8th Socket bit

3/8 Drill bit

Crimping/Curling

Pop Rivets

Rivet gun

Cutting Tools

Scissors

Utility Knife

X-Acto Blade

Drawing Tools

Marker (sharpie)

Electronic Tools

Jigsaw

Dremel Kit

Files and Rasps

Rasp

Hammers

Hammer – standard

Hammer – rubber mallet

Measuring Tools

Triple Beam Scale

Mold Making Tools

Paint Scraper

Power Tools

Cordless Power Drill

Sander

Heat Gun

Powered By Compressed Air

Binks Paint Gun

Gel Coat Gun

Screwdrivers

Phillips Head Screwdriver

Sculpting Tools

3/8 Board (Clay Cutting Board)

Thin Clay Spade

Wire Clay Cutter

Sewing Needles/Pins

Basic sewing kit

Other Tools

Hair Dryer

Hot Glue Gun

Large Injection Syringe

Spray Bottle

SUPPLIES

Aluminum foil (regular household)

Air Duster

Aluminum Sheeting (can be cut with scissors)

Aluminum Foil with Acrylic Adhesive

Coarse grit to fine grit sandpaper stock

Glue Gun Sticks

Hose Clamps (size varies)

Masking tape

Mole Skin tape

Paper towels

Several Paint Sticks

Skull cap

Wedges

Wooden dowel

Zippers

HEALTH/SAFETY PRECAUTIONS

When working with toxic and/or dangerous materials or tools:

ALWAYS read labels for appropriate use guidelines

ALWAYS wear a high-grade respirator

ALWAYS work in a well-ventilated area

ALWAYS protect your skin

ALWAYS wear eye protection

Artist BiographyAlec Gillis

Academy Award nominated FX Wizard | Co-Founder Amalgamated Dynamics Inc. | Founder Studio Gillis

See Full Bio

Additional Purchasing Options

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