Casting and Moulding The Horns

Now that the horns have been sculpted using wire and modroc, you can now start to cast and mould them.

Required Materials:

* Glue gun                                             * Modroc horns
* Plastic board                                       * Spatulas
* Silicone                                               * Catalyst
* Thixotrophic(thickening agent)              * Scales                                                  
* Medium size pain brush                        * Paper towel
* Resin                                                  * Plastic red head
* Modroc

1. Pre heat the glue gun and place on a plastic board out of the way.

2. Once the glue gun has heated up, place the horns onto the plastic board and glue down the bottom. You will need to hold the horns in place while they dry, this should take about a minute to dry.

3. The next stage is creating a flexible mould so you will need to do the same technique as you did for the face cast. Again mix together the two liquids (silicone and catalyst). Start by measuring 100 grams of silicone to a plastic measuring jug. Using a clean plastic cup measure 10% of the catalyst, which means 10 grams will be added into the mixture.

 The catalyst is a bright red liquid which makes it easier when it comes to mixing them both together. The liquids need to be mixed thoroughly using a wooden spatula so that all the white substance turns to a light pink colour. Pour the contents into a clean cup and thoroughly mix again, getting rid of any white liquid.

4. Now drizzle a small amount of Thixotrophic to thicken the mix. You can now start to apply to the face using your finger to push the mix into the eyes and nose area. This will also help the air bubbles to escape.

5. Using a brush apply using a brush over the horns to create a thick layer. Use a spatula to get rid of any drips.

6. As it's drying, damp a paper towel and pad on the mould to neaten out any brush marks and then leave to set.

7. Now for the last process part one of moulding is casting the mould. Again you will need to create a Modroc jacket for the horns. It is exactly the same technique as you did for the face cast.

8. Once you have done this remove the plaster jacket from the horns.

9. Now remove the pink rubber from the horns, if it doesn't come away easily you will need to create a slit up the side of the pink rubber so it will be easily free from the modroc.

10. Place the pink rubber horns back into the plaster jackets. My jackets did not set properly and they were very flimsy.

11.  Now hold the rubber horns in the jackets over a bin and pour in the resin. Remember to keep rotating the horns and tip the back and forth so that the resin covers the inside of the rubber mould.

Do this until the resin turns white.The plaster jackets that I created were not strong enough and ended up leaking once resin was poured through. This may have been a problem but things worked out well afterwards.

12. Take of the modroc jacket and peel off the rubber mould and then you are left with two resin horns. These are very light weight and can be used in the pre-made holes for the horns.

I realised after moulding both horns that they would not stay in the prosthetic piece on there own. I needed to think of an effect way of holding the horns in the prosthetic piece without them falling out. I asked my tutor for advice and he suggested creating a wire strap going through the horns and making it fasten at the back of the head:

I decided that this probably wasn't a good idea to use the wire and wanted to create something that was going to be comfy for my model to wear. I asked for my tutor for more advice and suggested that I make a skull cap for my model and glue the horns on. On reflection I did not think of this at the time as I was feeling a little anxious that the assessment was sooner than I thought and I hadn't thought of how to hold in the most important bit.

13. Using the modroc technique start to create a cap shape on a plastic red head. Apply two - three layers. Leave it to dry until it is fully set.

14. Once the cap has set apply the prosthetic piece to a red head. But first you need to gently tear the foam inside the horn as this is where the resin horns will fit. Take a permanent marker and draw round the prosthetic holes.

 15. Remove the prosthetic and now glue the horns onto the cap. These will dry in a few minutes.

16. This is what the prosthetic piece will look like now the horns are in place.

Look out for 'Practising The Application' for the next processes and painting the prosthetic piece and horns!