Editor's note: Bill Doran makes armor, costumes, and space guns as Punished Props, and has written a series of books teaching foam armorsmithing. Bill recently stopped by the Tested office to drop off a few small figures he made, and shares how he made them in this guest article.
I've had this idea noodling around in the back of my head for quite some time. Since I was going to be swinging by the Tested office this month, I figured it would be a great time to knock out this quick little project: miniature figurines of Will and Norm's blockhead characters.
I had less than a day to build these guys from scratch, so most of my build decisions were based on whether or not I would have to wait for things to dry or cure. From start to finish, this entire build took less than 8 hours.
I started by planning out the sizing on all of the figure pieces based on a screen cap from the Tested website. I measured out all of the sides of each piece and prepped my material.
I ended up going with a high density, urethane tooling foam for this build. I wanted something that was easy to cut and shape, but was banking on not needing to fill, prime, and sand the surface at all, since that would add too much time to the build. This particular foam is so dense that it feels like stone! I got it from a company called 5 Axis a while back. They used to sell their off cuts on eBay.