Moulding the suit

I made silicone moulds from the foam suit with rigid mother moulds made from modroc and Jesmonite.

A thin (as it comes) coat of Repsil E30 was put all over the item, followed by a couple more thickened coats:

Then modroc and Jesmonite was used to make a multi-part mother mould:

Here is the rubber piece removed from the mould, and then placed back in the rigid mother mould:

I used Smooth-on Smooth-Cast 65D to make the cast by tilting the mould around as the resin set to make a hollow cast:

Here's the original foam piece, and the plastic cast side by side:

I then did the same for all the pieces, here are helmet pictures:

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