polystyrene

Desirée, my dear dead manta ray

Posted by hil

Manta ray

This is the big dead manta ray prop that I made for the Street Theatre’s production of Jacques Brel is alive and well and living in Paris.  Sadly Desirée – my name for her  – was cut from the final production, but I loved making her.  Manta rays are such awesome creatures!

Because she had a wingspan of over 2 metres, I decided chalk on the floor was a good way to start drawing up a pattern. I also bought myself a little plastic model of a manta to refer to, which turned out to be useful.

Manta ray

From this I traced a pattern onto butcher’s paper and from there onto sheets of polystyrene which were then built up and glued into a block.

Manta ray

I also decided to insert a strip of thin plywood into the underside right across the width of the wingspan, so that the wings would be protected from breaking, especially at the tips. I also did that with the fins that I added.

Then much shaping with a really sharp knife, a narrow power belt  sander, and sandpaper. I decided to keep the surface a bit rough, which often makes it easier for an audience to read.

When I use polystyrene that will just have a painted finish I skin it with muslin first. Here you can just see some of the muslin draped over the spray adhesive can on the right.

Manta ray

I usually add a little bit of latex to the first coat of paint to help make everything stick to the styrene.

Manta ray

Then it’s on to colouring; for the final shading I used spray paint so that the colours merged softly. It was tricky to seat in the eyes (painted and glossed wooden door knobs) and get the shape of the upper eyelid right.

Manta ray

There are a few more in-between photos in my photoset at Flickr.

Messy

Posted by hil

Studio

This is what my studio looks like at the moment. I’m making a large dead manta ray out of polystyrene. I wish it wasn’t so messy and that I didn’t have to wear a respirator all day, but it works nicely.

Flying ducks

Posted by hil

I’m working on several projects at once at the moment. One is making a set of those flying ducks that people had as wall ornaments when I was growing up. I’ve been lent a couple to model from, and looking at them up close I can understand their attraction, despite their kitsch reputation. Since the ones I am making are theatre props they only have to look like the real thing. Inside, they have an mdf structure, and I have bulked them out with polystyrene. I like carving styrene, except for the mess.

Flying ducks

The next part of the process is covering the shapes with a commercial paper mache pulp. It starts as a dry mix, and when you add it to water it turns into a thick paste, which can be smoothed on and sticks to most surfaces. Here I’m half way through adding the paper mache to the big duck:

Flying ducks

The pulp takes a couple of days to dry, but I’m always impatient with things like this, and I have been hurrying it along by putting the ducks in the sun,

Flying ducks

and the oven:

Ducks in the oven

I’ll have to add more detail to the shapes, like the eyes, tails and feather patterns, and then its a matter of getting the surface smooth and painting it to look like china.

We have four beautiful white pet Indian Runner ducks, and it was funny to see them charging across the back garden in a line just as I was photograhing these in the kitchen.

Instant grab spray adhesive for polystyrene

Posted by hil

I’ve found a spray adhesive that sticks polystyrene with an instant grab – this is worth shouting about! Its in the 3M range, and is called Multi-Purpose Spray Adhesive. I’m amused by this graphic on the US site:

Botticelli because there is a humourous appreciation there of the beauty and godsend of finding the right glue for the job, but also because it reminds me of my Darcy Venus from Pemberley days.

Just about all glues eat polystyrene. White PVA glue and epoxy resins like Araldite are the exceptions, but they take time to dry, and the work has to be clamped meanwhile. One or two of the liquid-nails-type adhesives can be used, depending on the job, but they melt polystyrene to a certain extent, and are lumpy.

The can of Multi-Purpose Spray Adhesive that I bought here in Canberra doesn’t have the ‘Super 77’ tag on it, and is half-green-half-black rather than red. I’m assuming that its just different packaging, and the content is the same, but it might be worth checking. It’s a 467g can, boasts 6 times more coverage than any other competitor, and is expensive: AU$29.95. But its worth it.