Danakin's CASEY JONES Hockey Mask

[Danakin]

Hey everybody! I don't post here often, I mostly just look around at all the cool stuff people post but I finally have something to add. One of my main hobbies is costuming and prop building. I've focused mainly on Star Wars over the years but lately have started to branch out into my other fandoms. A couple months back I started working on a Casey Jones hockey mask and costume and I wanted to share some photos.

The mask started out as a Pepakura template which I printed out and cut out of thin cardboard. Once assembled I began coating the front and back with bondo and resin. Here was the first pass.



Here’s the second pass, after lots of sanding and spot putty.



At this point it was easier to see the asymmetry so I got to work on that. I also cut out the eye and mouth holes.



Originally I had planned on making a mold and casting the mask in resin but an opportunity came up that allowed me to get some vacuum formed copies made and so I did. I shot some video of the process and have the clips compiled in this Youtube video:
http://youtu.be/twjB4HzI7gk

I was very pleased with the results. I feel pulling them from styrene made them feel more like a real hockey mask (just not as durable, of course).

Now, you can't be Casey Jones without an assortment of sports equipment to lug around. I picked up a nice golf bag (in Playmates' pale green!) and some clubs from Goodwill. I also picked up some cheap bats here and there but I had to make the hockey stick myself. Apparently there isn't a lot of hockey played here in Nevada, go figure...



I debuted my finished costume at Phoenix Comic Con at the end of May. It received an surprising amount of attention, I guess there's more TMNT fans out there than I realized. I brought a few different shirts to switch into throughout the weekend, including a hoodie for more of a movie-look (with wig!) and a bloodied t-shirt, complimented by a battle-damaged mask. Here's a couple shots from the weekend.