Even though The Zoidberg Project has been wrapped up for a while now, it’s not over. I got sidetracked back in May with the Gore Magala build for Capcom's Monster Hunter 4 Ultimate display, and I still owe you all one more article!
So let's back track a bit….back to early April. Leading up to the debut at WonderCon, I had a ton of finishing to do on the Zoidberg costume. The feet that Carson and I sculpted and molded needed to be cast up and painted. We opted for a simple latex and polyfoam casting. To make this cast, we brushed in about four or five good coats of latex into the mold, giving plenty of time for them to dry between layers. If you don't let the previous layer dry enough, you will end up with wet layers sandwiched between dry layers, which will make the skin too soft and prone to stretching out of shape.
Since this mold for the feet are stone, I could have just filled it up with latex and let it set for an hour to form a "skin" around the outer edge, then dump the excess latex back out into the bucket and let it dry. But I felt that manually brushing in a few layers and drying them with a hair dryer between layers would be the fastest route. Once this layer of latex skin is set up, I mixed up a batch of Flex Foam 3 from Smooth-On and just rolled it on the surface until it started foaming up. I didn't need it to be a solid foam casting because I still need room for my food and ankle inside.
This finishes the casting, which could then be demolded and trimmed up while the second foot was being done. I like to use an electric turkey cutter sometimes when I'm trimming foam, and it helps to hog out big sections quickly. Once I find the right fit for my foot, I used a little Barge glue to tack the latex down to the foam, as sometimes it can delaminate. That was it for the feet, but we all know that Zoidberg doesn't walk barefoot.