Step 1: The first thing we created was a fitted, helmet-like base for each headpiece, made out of industrial felt. A basic coif pattern
was used to cut out the pieces which were then hand-stitched together. The finished felt helmets were then soaked in hat stiffener, stretched over wig blocks and dried so we had specific sizes that fit snuggly on each actor's head.
Step 2: For the outer structure of each headpiece I started with a 12" diameter styrofoam ball which I carved into the basic shapes of each animal head (for the teddy bear and clown I just started with the round shape of the styrofoam ball itself).
Step 3: After the basic head shapes were created, I covered them with plastic wrap, then stretched wet double-thick buckram over them. I did the front half of each head first, then the back half. After the buckram dried and stiffened, I stitched the two halves together, adding additional buckram pieces as necessary to get the desired shape. Millinery wire was sewn around the bottom edge of each headpiece to help reinforce the structure.
Step 4: The felt helmets were then placed inside the buckram structures and sewn into place. After an initial fitting with the actor, eye holes were marked and cut out. I then glued black plastic mesh over the eye holes so the actor's could still see but their faces were not visible. For external features such as ears etc. I used card stock mockups to get the correct proportions.
Step 5: A layer of batting was then glued to the buckram with spray adhesive. Finally, the headpieces were covered with their fabrics or fur. External details were either painted on or attached to create the final looks.
was used to cut out the pieces which were then hand-stitched together. The finished felt helmets were then soaked in hat stiffener, stretched over wig blocks and dried so we had specific sizes that fit snuggly on each actor's head.
Step 2: For the outer structure of each headpiece I started with a 12" diameter styrofoam ball which I carved into the basic shapes of each animal head (for the teddy bear and clown I just started with the round shape of the styrofoam ball itself).
Step 3: After the basic head shapes were created, I covered them with plastic wrap, then stretched wet double-thick buckram over them. I did the front half of each head first, then the back half. After the buckram dried and stiffened, I stitched the two halves together, adding additional buckram pieces as necessary to get the desired shape. Millinery wire was sewn around the bottom edge of each headpiece to help reinforce the structure.
Step 4: The felt helmets were then placed inside the buckram structures and sewn into place. After an initial fitting with the actor, eye holes were marked and cut out. I then glued black plastic mesh over the eye holes so the actor's could still see but their faces were not visible. For external features such as ears etc. I used card stock mockups to get the correct proportions.
Step 5: A layer of batting was then glued to the buckram with spray adhesive. Finally, the headpieces were covered with their fabrics or fur. External details were either painted on or attached to create the final looks.
