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Unread 10-22-2012, 09:45 PM   #1
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Join Date: Oct 2012
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Smile Borg

I am looking into making a Borg costume.. I am curious how they originally made this one.

the part around the guys collar, looks like rubber with embedded wires..
is this flexifoam?

I have made a duct tape form of my torso so start making a pattern but I would like to plot the steps i need to create this wire backing

I was thinking to make a slab of clay.. and embed wires into them densely. and then create a negative silicon mold and then make a positive cast from Flexifoam (unsure the weight)
dyed silver and then painted black to age it.

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Unread 10-29-2012, 10:49 AM   #2
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Join Date: Jul 2003
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When you cast with foam (I've only messed with Smoothon's Foam IT! line) you can just pigment it black outright and brush in their line of metallic dust to give it that "shine" of metal. Painting flexible stuff is difficult since paint normally cracks when stuff bends.

Are you planning on making a mother mold for the silicon mold? The rule of thumb is that casting rigid things gets a flexible mold and casting flexible things gets a rigid mold.

For my rubber casting I use fiberglass just to save a couple of extra steps.


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