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Joe Blow (Part 6 – Replacement Faces)

Continues from Joe Blow (Part 5 – Head Mold)

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So… replacement faces.
Low-tech, but quite satisfying.
The first face (the how-to) took about 3 months, the second – about an hour, with a few tries and improvements, then it was about 15-30 minutes each. Now I make them like sugar cookies, a few minutes, depending on the complexity of the facial expression.

My 3-part hard push mold

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living doll polymer clay

Fill in and bake.
The oven is Deni 10400 Quick-n-Easy 10-4-Quart Convection Oven.

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Drilled holes, filled them with magic sculpt epoxy putty, inserted 4×8 mm magnets

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There are two allies in this battle: body powder and translucent liquid sculpey
Translucent liquid sculpey makes baked clay sticky – if I need to add uncured clay.
Body powder makes clay (and everything else) non-sticky.

First I will make the slivers – they are baked clay pieces which hold the hardware. It is not possible to pull the face out of hard push mold without distorting if there is nothing to grab it with. These slivers will help to pull the face right out.

Sprinkle body powder.

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Tap on the side a few times- the body powder will coat the entire surface evenly.

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M3 T-nuts and M3x16 threaded rods

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Grab with pliers by the threaded rod and pull the sliver straight up.

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It is helpful to get the weight of the first sliver to speed up the process of the other ones.
Dust a glass tile with body powder, tap on the edge to spread the powder evenly, set the first sliver on top of it.

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Bake well, 30 minutes at 275F, so that the slivers are not crumbly.

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Drill

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Paint with translucent liquid sculpey to make the sliver sticky.
Fill the holes, insert M3 hex nuts (carbon steel, stainless steel ones do not attract magnets). The store only has stainless steel, carbon M3 hex nuts are on the way.

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Get the depth – where the hex nuts need to be sitting on top of the magnets.

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Bake.
Unscrew the threaded rod.

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Dust the face mold with body powder.
Tap on the edge to coat the mold evenly.

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Paint the sliver with translucent liquid sculpey.
Put the clay into the face mold carefully without disturbing that body powder coat too much and press down.

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Put the eyes into their places.

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Press 2 parts of the mold together. For good measure, put it on the floor and step on it.

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Remove excess of clay.
Close and press again a couple of times until all the excess clay is out.
Screw the threaded rod into the middle hole.
Grab with pliers and pull carefully vertically up.

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Put the back of the head on the head stand.

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Smooth out the edges of the replacement face.
Pull out gently the eyes, smooth out the eye sockets and put the eyes back.
Eyes – drilled delrin balls, 7mm dia.
Brush – cat tongue smoothing brush

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Add the details, like nostrils and corners of the mouth.
Make the facial expression.
The tool is a color shaper taper, size 0.

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Push-cut around a with sharp tool. The tool I am using is a sharpened micro half spatula

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Arrange on the glass tile and bake.

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To be continued…

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