The rough head sculpture, done in white plastilina. Ted's Hydrocal head cast receives three coats of Alcote dental separator. After drying the Alcote, the plastilina is sculpted onto the cast.
The whole head soaks in a tub of water overnight, which reactivates the Alcote into a slippery film, loosening the clay. I slice the clay where I want the appliances to overlap. Here the chin, forehead and rear skull have been removed and placed on the section molds.
	Henrietta's bloated plastilina body is done. In preparation for the fiberglass mold, we spray the clay with clear acrylic and several coats of PVA (a standard release for fiberglass).
Black gel-coat resin is used for the first layer. The color makes troublesome bubbles easier to spot. I brought in fiberglass expert Don (Cocoon) Pennington for the job, and he fabricated a pristine mold.

Ted excitedly tries on the first polyurethane foam test suit. To create the foam skin, we coat our fiberglass molds with wax and silicone release agents (BJB 86 release fiber resin FR 1000), then spray with a urethane film to get a good "skin" surface. Ted's fiberglass body is placed between the fiberglass negatives, and the molds bolted together. 1014 fiber resin by Polytech is the foam used. Several measured batches are prepared using jiffy-mixer drill attachments. Timing is critical -- a difference of a mere three seconds can result in a bad mix.