Version 1 Mold
The Acolyte mold is made out of Bondo.
It's actually the very first mold I ever made (which was for a Revan-esque bounty hunter mask I did as my very first project!), reworked into a different shape (on the left in the photo below).
Since my BH mask turned out decently (at least I think so!)...
… I decided to reuse that mold, reshaping it slightly into the Sith Acolyte.
So, I added a ton of bondo to the original BH mold, turning it into a giant blob of hardened goo, using some ABS and HIPS plastic scraps for support on the inner side. The great thing about using plastic in the mold making process, is that BONDO does not stick to it very well; after the bondo cures, the plastic can simply be peeled off without damaging either component.
Hours upon hours of adding bondo, sanding, adding more bondo, having a beer, adding more bondo and more sanding, the Acolyte mold finally took shape.
But, after walking away from it for a while, looking at the reference material, and then coming back to it, something didn't feel quite right. I did not like the shape, I realized. So, once again, I went to applying bondo, sanding, rinse and repeat.
Finally, I arrived at a shape that I liked a lot more. I used an electric sander with 60 grit sanding discs to get there, and then changed to 120 grit to smooth it all out.
After some hand sanding using 150 grit paper, and building up the chin with some - you guessed it, BONDO! - the mold became this. It is hollow on the inside, and at any given point on the surface, is about 1/2 thick.
I carved the eyes all the way through to the inside, and drilled a few small holes inside the mouth at the sharpest feature points in order to help the plastic fold over the edges with minimal detail loss.
* * * * * * *
- Version 1 Mold