Friday, April 13, 2012

The class is pain 101, your instructor is Casey Jones

Ever since I was a kid I have always loved Teenage Mutant Ninja Turtles. My favorite turtle when I was a kid was always Leo, but the older I got I related to Raph more. I always loved the scene in the movie where Ralph first meet Casey Jones. After watching the movie yesterday, I'm thinking why hasn't anyone built a screen accurate replica mask yet? Well the time is now.

Start off with some reference:


I figured the easiest way to build this mask would be to use a program called Pepakura Designer. Pepakura Designer allows you to create paper craft models from 3D models. Now personally I hate working with paper craft, but the class is pain 101.

To start off, I contracted a very talented artist to 3D model the mask, as I am not that familiar with 3D software. Within a span of 24 hours he came back with this:


I was absolutely amazed at how fast he was able to produce this. Unfortunately the amount of polygons in this rendering was too high for Pepakura Designer, so we had to lose some of the detail. But all in all even with the loss of detail it was still perfect for a starting point.

This is how it looked once it was imported into Pepakura Designer, unfolded and ready for print.


Next step, print, cut, score and glue.






Now that I have a 3D paper model I can start the wonderful world of fiberglass.




Some features were lost when the file was converted to a lower Polygon count, so I had to do some cutting and shaping to get the correct look back.



Pieces of cardboard were added to fix the nose area. Then it was fiberglassed, filled and smoothed.


Next step was to add the brow lines. To do this I cut the shape I wanted out of ABS and then epoxied and screwed the pieces into place,








More filler was added to cover the screw holes and hide any seems. The same thing was also done for the nose.


Lots of filler and spot putty.
 


Primed and ready to cut the mouth slits.


For this I designed a template in Adobe Illustrator, lined it up, taped it down and cut it with a Dremel tool.


More spot putty.

Finished piece primed white. There are some minor changes I still want to make which I will show later when I am finished.



17 comments:

  1. Hey would you mind making me a casey jones mask plezzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzz

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  2. Oh sorry forgot to ask would there be a price for the mask

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  3. Wont be making anymore of these till around Halloween time. They will be auctioned through ebay with a starting price of $99.

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  4. I AM going to buy a Casey jones mask sometime soon with Halloween right around the corner. I really want yours! Please let me know when you have 1 available!

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  5. Ill be selling more around Halloween time, but I dont have any available right now.
    -Todd

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  6. Ever get around to making more of these to sell? None of the others on ebay look worth the money!

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  7. The material was ordered today for it. Gonna try and cast one or two up in between making bane masks.
    -Todd

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  8. Is there any way i could get the Pep file?

    zanderyurami@gmail.com

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  9. So, how much would one of those cost me?

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  10. Hey Todd, was wondering if you're still making these. Would like to get one. If u can email me please at svtcobra2088@hotmail.com. Saw you had them on eBay last year but lost in the bidding. Any details on them being made again would be appreciated. Thanks dude.

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  11. Hey Todd I came across your page via Google I'd love to buy a mask if you're still making them in time for Halloween. For people with bigger heads could modifications with measurements be made? Email me at Aaronmsaucedo@Gmail.com

    Thanks and awesome work!

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  12. Hi Todd, I was wondering if you're still making these CJ masks

    Email me at malkav1369@gmail.com

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  13. can you send me the file .pdo?

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  14. Hi I am also interested in buying a Casey Jones mask.

    Could you please email me at larsen.matthew12@gmail.com

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  15. Hi, Im also interested in buying a Casey Jones mask

    Please email me at larsen.matthew12@gmail.com

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  16. are u still making copies of the casey jones mask because im interested in buying one email me back at diazd87@gmail.com

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  17. i was wondering if you were still making these casey jones masks because i am very interested in buying one email me back at diazd87@gmail.com.....i may have already messeged you but i wasn't sure if it went through

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