Casey Jones - Teenage Mutant Ninja Turtles

Hi all, Ive got a new commission to show. I was approached by someone a while back whom had interest in commissioning a Casey Jones Mask for Wondercon.

The client was unsure of which version he had so I had to recommend taking a look at Dave Rapoza's fantastic concept art

I really sold the idea to him a little while later when I created a concept renders for him in zbrush.

the first step was to do the unwrapping for pepakura,

From this point the mask was reinforced with urethane resin, I used smooth cast to reinforce the interior of the pepakura. With a master I like to build up the thickness of the interior of the pepakura so I can sand the peaks of the pep down.

the mouth was too long for the client so it was trimmed to fit the proportions of his face better

after a great deal of bondo, sanding, and more bondo

and primered

some more contouring and here is a quick shot of the client testing it

heres a final shot before molding

ill post a pic of the molding later

final product after airbrushing

happy customer