This process is based on the method describ

This process is based on the method described in Flint Mitchell's book, the section by John Burkhalter. I began with a single sheet of 4’ X 8’ X 2” Polly-styrene. Cutting it with a power jig saw.

Using a jig saw I cut circles, slightly larger than the torso in various diameters to fit the top and bottom curves. They are held together with white glue. I also ran a small long metal tube through the centers of the pieces keeping them all straight. The tube will also be used to keep the templates from wearing out the center hole.

I cut a template from a full size drawing and put it onto a piece of Plexiglas. It was then mounted to a pivot in the center of the foam pieces. Using an electric carving knife I got the shape close, then finished with a belt sander until it matched the template. This is when my wife's love was proven! She allowed my to user her knife, no problem, but the shreds of foam were the real test. I found spraying myself with anti-static spray helped reduce the amount brought into the house.

Like a giant puzzle I assembled the remaining pieces into the body of the torso making it the correct height.

I then finished trimming it to size cutting the mouth arm and vent holes. It's finally starting to resemble our old friend! Here is the template to the mouth opening I used Drawings.htm

This is when it got ugly! As soon as I applied the first piece of fiber glass the foam began to melt! I then covered the entire torso with masking tape. This made a barrier around the foam allowing me to safely finish covering it with fiberglass. Later I had to heavily bondo in the sunken areas. Vince adds "I know it's too late now, but the solution for glassing styrofoam without melting it is to coat the foam with two or three coats of good latex paint."

Here is the torso with the first layer of fiber glass. Notice the deformity on the right 'mouth' opening

Here is another view.

Here is the dissolving of the foam, Layer by layer. This part was really fun and messy!

At last an empty shell! A quick shot of sliver paint really shows all the imperfections. Another layer of fiber glass and matting is applied to the interior. You can see the area where the first application of gel ate away the bare foam.

At this point I was ready to give up! It seems no matter how much you sand and fill it's still too wavy! "Don't quit yet!" my wife said.

Don't loose hope. It's finally ready for the ribbing. Too late I discovered the arm holes are not centered from the top to the bottom! (Good excuse to later upgrade to a club torso when funds are better!)

Here's the torso after receiving the new arm sockets from Mike Joyce's torso Beforer getting Mike's help I was counting on the arms to help hide the poor condition of my torso's arm sockets.

New sockets are fitting in nicely. This really makesa big improvement. Thanks Mike!

Torso as it looked in January 2000