Hello peeps! I've wanted to do this for a bit now, and I figured that since I'm going to Australia's biggest gaming convention, now's the time.
I already knew that I wanted to build the basic shape out of toothpicks and styrofoam balls, as that's what I did for organic props back in school. This allows the props to be easily built, lightweight, and most importantly, easily throwable.
So I grabbed two packs of mixed size balls and some toothpicks from a local craft store and landed at a pretty accurate shape by the end of the night.
The next step was to hold the balls in place: a layer of aluminium.
Since it was super easily moldable and held it's shape on the form without glue or other substances, it made it a super easy method of adding some strength to the build.
After a full layer was put on, I realised it wasn't holding together as strongly as I hoped. So I grabbed a small roll of cling wrap and bound him tight.
Next step was to apply a layer of painters tape to Terry (his name btw).
This allowed to have a smooth, continuous surface across him. I also felt I was lacking some shape in certain areas, and added some half-cut balls to bump up certain areas to make him more accurate.
Next was wires for the "eyes" and the legs. I chose 1.25mm wire for the eyes, and 2mm wire for the legs.
I reckon 2mm wire was a perfect choice, as I can still pose and move the legs freely, while they still have enough rigidness behind them to stay in place. (Standing, grasped onto an arm, etc.)
Simply cut the wire to the length I wanted and shoved it into him. I kept adding hot glue to the hole, so the wire would bring some along with it (hopefully) and get stuck in place. Then I added some hot glue points to the outside as well, to really stop it from sliding out.
Aaaaaand now we're up to date! Today I've added a layer of upholstery foam to his body, plus shoved some onto all his wires.
I must say, this is the first moment in this build where I've looked at him and gone: "Oh yeah. That's a flood form."
Next thing for me to do is create some patterns for his "skin". I've got tons of thin white leather which I will be wrapping him with, bunching it up in certain areas to keep his head-ridge-folds loose etc.