I was commissioned both masks of Mr. Bushido from the anime Mobile Suit Gundam.

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I decided to use Apoxie Sculpt (epoxy putty) to sculpt the mask master. I used this air-dry putty over clay because my sculpting skills aren’t good enough to produce a finish smooth enough to simulate metal. The dry putty can be carved, Dremeled and sanded to a smooth surface before it is molded.

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Since Apoxie takes a few hours to dry, I used Bondo to correct geometry and reshape features to make the mask symmetrical.

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You can see from the pink Bondo areas how much had to change from the Apoxie stage to get to final sculpt.

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I gave the mask several thick coats of filler primer to smooth out the surface and point out any imperfections.

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To further define the bevel around the eyes, I scribed a thin line around the color break.

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The final mask ready for molding.

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I used Smooth-On Stroke to build a thick silicone mold over the mask. The stuff goes on like cake frosting and allows you to quickly build a stable mold wall.

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I soaked a cheap shop rag in plaster to make a mother mold over the silicone so that the mask can retain its proper shape.

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The cured mold pulled off the master.

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I poured some Smooth-Cast 65D (formerly Smooth-Cast Roto) and slush cast the mask in several layers.

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The de-molded mask! A perfect copy including my eyes and mouth.

The de-molded mask! A perfect copy including my eyes and mouth.

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For the half mask, I cast a second copy and marked where I’d need to change it.

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The half mask with excess cut away and the scribed lines filled with putty.

To attach straps to the mask, I bought some bathing suit hooks.

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Tacking the hooks in place, I poured a small amount of resin in the corners to lock them in place.

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A base coat of gloss grey.

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I painted the inside of both masks with flat acrylic black paint.

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After the red areas were painted, I applied a protective coat of matte finish Crystal Clear. The half mask here shows can see how much of a difference the matte finish makes.

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The finished full mask.

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The finished half mask.

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Plans are available HERE. Or if you want to save yourself a bunch of sculpting, buy one my kits!

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