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Markus G. Nowak's Journal
New fursuit head 
22nd-Jan-2012 05:12 pm
Fussel
The photos in my tutorial at http://www.fursuit.de/ are from several fursuit heads and my methods changed over the years. Some people are confused by this. Last week I got the urge to build a new fursuit head (while I watched Qarrezel working on Fisk's cheetah mask - fursuit making can be contagious).

This time, I also made pictures of the intermediate steps that I have only mentioned in the past. The head is not finished yet - right now I'm waiting for the painted eyes to dry.


Bend an aluminum profile (20x3mm) to fit on your head - this is the basic structure on which the plastic mesh will be attached. It should sit very smooth on your head - from the back of the head to the forehead.
Bending the basic structure, bend a aluminum profile 20x3mm to fit your head

Attach the plastic mesh with elastics. Notice that the elastics do not cross each other on the insides of the head.
Plastic mesh attached with elastics elastics do not cross each other on the insides of the head

Every cut in the plastic mesh should be smooth - remove all sharp edges. Cut the mesh on the sides to the middle.
every cut in the plastic mesh shut be smooth - remove all sharp edges cut the mesh on the sides to the middle

Build a shape that sits comfortable on your head - start with the mesh stripes on the ends. Make shure the ends of the cable ties are always pointing outwards.
build a shape that sits comfortable on your head - start with the mesh stripes on the ends make sure the ends of the cable ties are always pointing outwards

Close the holes and cut the mesh if there is already enough material.
close the holes cut the mesh if there is already enough material

Make sure the mesh does not reach your ears.
make sure the mesh does not reach your ears

Cut the mash for the sides of the fursuit head.
cut the sides of the fursuit head

Bend the sides round and use cabel ties to fix the position.
bend the sides and use cabel ties

Attach the sides to the head.
attach the sides to the head always check the symmetry

Make sure that there is enough space for your ears in the sides - and maybe a 9V batterie.
make sure that there is enough space for your ears in the sides - and maybe a 9V batterie

Cut the mesh for attaching the eyes and bend it.
cut the mesh for attaching the eyes

Find the right place to attach the eyes. Find out where your eyes will be. If you want to wear glasses inside the fursuit head leave enough space for them.
Find out where your eyes will be

Draw a circle with the same diameter as the plastic eye and draw a straight line thru the middle.
draw a circle with the same diameter as the plastic eye and draw a straight line thru the middle where to drill the holes

Bend aluminum profiles (20x3mm) - these will hold the eyes - the eyelids go between the eye and the profile.
bending aluminum profiles 20x3mm

Attach the mesh over the eyes and use the aluminum profiles to bend it in the right shape. Reinforce the plastic mesh with polycaprolactone (you could also atttach the profiles directly to the mesh).
attach the mesh over the eyes and use the aluminum profiles to bend it in the right shape plastic mesh reinforced with Polycaprolacton plastic mesh reinforced with Polycaprolactone

Make eyelids with polycaprolactone.
eyelids made with Polycaprolacton adjusting the angle of the eye to the front

Attach mesh below the eye.
attach mesh below the eye

Attach the muzzle and test the eyelids.
attaching the muzzle and testing the eyelids

Check whether there is enough space for glasses.
checking if there is enough space for glasses glasses go inside the plastic eye

Attach a leaver to the eyelids and bend steel wires to attach them (to have more room for the glasses).
Attach a leaver to the eyelids and bend steel wires to attach them

Make shure the eyelids move smooth - change the holes if they scratch on the plastic eye
make sure the move smooth - change the holes if they scratch on the plastic eye

Cut a form out of thick cardboard that fits to your chin.
cut a form that fits to your chin out of thick cardboard

Cut the outside of the cardboard so that it fits in the upper jaw.
cut the outside of the cardboard till it fits in the upper jaw

Bend a aluminum rod to the form of the lower jaw - based on the cardboard template. Cover the front of the lower jaw with polycaprolactone.
bend a aluminum rod to the form of the lower jaw - based on the cardboard template Cover the front of the lower jaw with Polycaprolacton

Make a base plate for the teeth in the upper jaw.
sculpt a base plate for the teeth in the upper jaw

Attach teeth.
attach teeth make sure the teeth can close attach more teeth



I tried to list all the important steps - some generic parts (like: how to work with polycaprolactone) are not explained.
Comments 
22nd-Jan-2012 10:28 pm (UTC)
I find it so cool how you are able to make these in a way I don't see many others do. =) This is coming along great and those teeth look amazing, wow. :D

Edited at 2012-01-22 10:30 pm (UTC)
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