This file is one of the Wolfstone archives of the Halloween mailing lists. You can find out more, and reach the entire collection here: http://www.pobox.com/~wolfstone/_r/HalloweenArchive.html This is a copy of Don Bertino's archive from http://www.calweb.com/~bertino/halloween.html on the subject of "Vacuum Molded". Minor changes have been made, mostly removal of E-mail headers and signatures, but the germane content is unchanged. - - From: Don Bertino Subject: Vacuum Molded faces On Tue, 30 May 1995 dbell at cup.portal.com wrote: > Vacuum molded inverted-relief faces > > So many projects, so little time. Like everything else... Ok... This has been driving me nuts! Have you found a cheap and easy way to vacuum mold faces? I have seen smaller ones for sale, but I would like to see a full sized one! :-) - - From: dbell at cup.portal.com Subject: Re: Vacuum Molded faces Date: Tue, 13 Jun 95 12:12:21 PDT Don Bertino asked: >Ok... This has been driving me nuts! Have you found a cheap and easy way >to vacuum mold faces? I have seen smaller ones for sale, but I would like >to see a full sized one! :-) Well, I'm hoping to commence woking on it, Real Soon Now! There are several sources for designs of relatively simple vacuum forming systems. In general, they rely on using a heat-softening plastic film, stretched over a positive mold, with a perforated substrate. You apply the vacuum through the substrate, and stretch the heat-gun softened film over the assembly. The task remains of obtaining the positive molds. Life masks in plaster are pretty easy. Now, if you're going to project an image on the mold, you probably want a very "plain", generic face; maybe even a wig head? Another option, once you have a rigid mold, would be to spray on and build up layers of film... - - Date: Tue, 13 Jun 1995 12:48:57 -0700 (PDT) From: Don Bertino Subject: Re: Vacuum Molded faces On Tue, 13 Jun 1995 dbell at cup.portal.com wrote: > Don Bertino asked: > > >Ok... This has been driving me nuts! Have you found a cheap and easy way > >to vacuum mold faces? I have seen smaller ones for sale, but I would like > >to see a full sized one! :-) > > Well, I'm hoping to commence woking on it, Real Soon Now! I am working on that homemade spider web maker this weekend... wellll... next week...welll next weekend.... :-) (BTW, all posted for halloween-l are being archived to ftp.netcom.com /pub/be/bertino/halloween starting tomorrow, I have saved everything, just trying to automate it :-) > There are several sources for designs of relatively simple > vacuum forming systems. In general, they rely on using a > heat-softening plastic film, stretched over a positive > mold, with a perforated substrate. You apply the vacuum > through the substrate, and stretch the heat-gun softened > film over the assembly. > > The task remains of obtaining the positive molds. Life > masks in plaster are pretty easy. Now, if you're going > to project an image on the mold, you probably want a > very "plain", generic face; maybe even a wig head? Would the easiest way to do this is find a cheap 8mm projector? Is there away to automate the rewinding of the film? Sort ta like 8 tracts were? (continus loop of film) > Another option, once you have a rigid mold, would be to > spray on and build up layers of film... Hmmmm, what would make a clear (transparnet or translusent (sp?)) film? Has anyone worked with that castolite? You know, the stuff pour over bugs or flowers or coins and make paperweights out of... (or am I getting confused with the name?) Then there is that stuff that you pour over burr table tops or rough surfaces, it flatens out and forms a smooth clear thick finish. It would have to be not runny, and you could pour or brush it (paint sprayer)?. I remember stuff that was a two-part mix, stir together and alot of heat was generated. And it harded in a few minutes to a hard clear block. I don't remember if it was runny or not... Hmm.. - - Date: Wed, 14 Jun 1995 08:54:35 -0700 From: milwiron at ix.netcom.com (D.D. ) Subject: Re: Ads >Could you tell me how big the busts that you have made are? >Height/width/depth? Is there good definsion(sp?)? (very detailed?) > >Thanks! Tom made the plaster mold from a full size skull model, he used clay to fill in the deep spots and any undercuts. He found that too much detail especially sharp detail worked against the watching effect of the bust. He's pretty artistic and used an airbrush to paint in shadows and some detail. He had copied a reverse bust I had bought a couple of Halloweens ago, it's called a "Wachoo" by the Optic Images Co. no address. They work very well when gently back lit and viewed from more than 10 feet away. The one I have I put in a window and black out the rest of the window so all you see from the outside is this face watching you, people see it as they walk or drive by. I'll check with Tom, if he has a spare I'll send it to you. - - Date: Wed, 14 Jun 1995 10:55:47 -0700 From: milwiron at ix.netcom.com (D.D. ) Subject: inverted vac-forms Heyyyy Don, I talked to Tom (see, I do have a friend) and he's going to send one of his skull "watcher" vac-forms to me. He says they're called anti-masks. If you send me your snail address I'll relay it on to you and you can use it for what you want. - - Date: Wed, 14 Jun 1995 07:41:18 -0700 From: milwiron at ix.netcom.com (D.D. ) Subject: Vac-forming book A good book for vac-forming is: Do It Yourself Vacuum Forming By Douglas E. Walsh 272 Morganhill Drive Lake Orion, MI. 48360 This book outlines a simple home setup. His plastic holding frames are a bit overdone. As I mentioned, I've always used plywood frames and staples to hold the plastic in an oven. He has a bunch of good ideas and lists sources for plastics and materials. This book was also in stock at Lindsay Publications (815) 935-5353 a mail order, strange and wonderful book seller (both the books and Lindsay). - - Date: Tue, 13 Jun 1995 14:10:05 -0700 From: milwiron at ix.netcom.com (D.D. ) Subject: Re: Vacuum Molded faces Hi ya Don, My ol' buddy Tom (I do have some friends, he may deny it)) has done the inverted faces based on a store bought one I loaned him. He clayed up the undercuts and deep areas on a full size plastic skull and pulled a plaster off the face area. The plaster then had some small holes drilled in it and sits on a wooden manifold hooked up to a good shop vac. He heats the plastic in the kitchen oven while it's stapled to a plywood frame (the plywood smokes a little) The clear plastic he's using was bought at American Science and Surplus. I think he found some Cellulose Acetate Butyrate which is easy to form. It's also easy to recognize because it smells like baby puke. For heat try around 325 to 350F for starters. He found that soft detail worked better than sharp to get the watching effect, he also had to play around a bit with the airbrushing. Tom worked for me years ago and learned his vac-forming in our shop. I do virtually the same process on occasion for protoyping but use a 2 stage vac. system. There are some books available on the subject of vac-forming that are advertised in R/C Modeler Magazine. Let me know if you'd like more details. - - Date: Mon, 7 Aug 1995 06:30:56 -0700 From: milwiron at ix.netcom.com (D.D. ) Subject: RE:Vac-forming and Archive Sorry that word should have been "hobbyist" not hobbiest as in "the most hobbi". Whatever that is. - - Date: Mon, 7 Aug 1995 19:06:05 -0400 (EDT) From: "Donna J. Logan" Subject: RE:Vac-forming and Archive I thought it meant whomever had the best Frodo costume.... ;-> On Mon, 7 Aug 1995, D.D. wrote: > Sorry that word should have been "hobbyist" not hobbiest as in "the > most hobbi". Whatever that is. - - Date: Mon, 7 Aug 1995 06:16:42 -0700 From: milwiron at ix.netcom.com (D.D. ) Subject: Vac-forming and Archives Howdy All, There is some information on vac-forming in our list owner's (Don Bertino) Halloween FTP site including my post telling of a good book for the home hobbiest. If your service allows you to do FTP here is how to find it- 1. Go to 2. Scroll to and open as in beer joint, this is where we can find Don. 3. Scroll to and open 4. Scroll to and open During peak hours you may have trouble getting to ftp.netcom.com. In Don's file you'll find the archive for the Halloween-L mailing list and alot of other interesting information including some great detail stuff on the Disney theme parks. If you have the ability to get to Don's site I would highly recommend it, he's compiled a ton of things you may not have known. - - Date: Mon, 7 Aug 1995 11:24:54 -0700 (PDT) From: Don Bertino Subject: Re: Vac-forming and Archives On Mon, 7 Aug 1995, D.D. wrote: Hi! > Howdy All, > There is some information on vac-forming in our list owner's > (Don Bertino) Halloween FTP site including my post telling of a > good book for the home hobbiest. If your service allows you to > do FTP here is how to find it- > > 1. Go to > 2. Scroll to and open as in beer joint, this is where we > can find Don. > 3. Scroll to and open > 4. Scroll to and open > > During peak hours you may have trouble getting to ftp.netcom.com. > In Don's file you'll find the archive for the Halloween-L mailing > list and alot of other interesting information including some great > detail stuff on the Disney theme parks. If you have the ability to > get to Don's site I would highly recommend it, he's compiled a > ton of things you may not have known. Thanks for the plug! BTW, just to add, they are in mailbox format. So if you have a mail reader, you should be able to use it to read the archives once you have downloaded them. They are split into 9 or 10 threads. Once there is a topic that generates enough interested, I split it into its own archive. The main general archive is called halloween-l. If you have any questions, please do not hestiate to ask! Current archives: gruesome.food outdoor.ghosts smoke audio.system halloween-l party.themes sources compressed.air* lighting plaster.castings spider.webs dry.ice maze skeletons vacuum.molded - -