Building the Star Wars Rancor Costume, Part 4

In the fourth part of our Rancor costume build, Frank Ippolito walks us through the mold and casting process of the large Rancor head sculpt. We discuss ways to add texture and “skin” to the foam suit, and start painting the creature just one week before Comic-Con! Thanks for following along with the build–we’ll be back next time with a debriefing of how the Rancor suit turned out. (Thanks to Model-Space.com for sponsoring this project!)

Shot by Joey Fameli and edited by Norman Chan

Comments (9)

9 thoughts on “Building the Star Wars Rancor Costume, Part 4

  1. Still want a Frankor head for my wall!! But where would I put it. over the head of my bed is empty, but imagine to waking up to the rancor every day?! lol

  2. Totally agree. I love watching really talented people ply their trade, and Frank’s work is just amazing. Seems like a great dude, too.

  3. When I was dipping my toe in special effects (usually I left it up to other people, I have no talent for making physical things, I’m a digital guy) there was one kind of latex and two kinds of paint, and no instructions available anywhere. Now there are a dizzying array of materials and tools available to all, with copious guides and step-by-step instructions, online and in books and magazines, letting you create a hundred thousand different kinds of cool things.

    I am impressed at how Frank calls each useful tool and material to mind, and knows how to construct a giant costume with incredible detail, both coarse and fine, in such a short period of time (including stopping to do these videos). Watching an expert in his environment is inspirational.

  4. At 10:10, says “We’ll be right back after this commercial break”, but the video returns immediately. Did a sponsor message get missed in editing?

  5. Did you have to seal the clay before applying the epoxy mould?

    Would unsealed clay prevent the epoxy from curing?

    Really enjoyed watching this creature come together. Thanks.

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