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VINTAGE GOALIE MASK DISCUSSION PAGE


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McGuillicuddy Profile
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Where to start?


After many years of thinking about it I'm gearing up now to start making my own masks. I have a million technical questions that I'm trying to answer by sorting through the information here (it is a shame that most posts are missing the good pictures that were originally posted).

One question that I have is what would be a good model to start with in my initial attempts. I understand the older, flatter Sawchuk-style masks are easiest. For me, I really don't have the same passion for those. I really am most interested in the masks of the 70s/80s. I'm thinking either a Higgins or an Esposito. Would love to try a Liut or Parent but I think those appear more advanced in several ways. Would appreciate any thoughts.
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McGuillicuddy Profile
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Re: Where to start?


And just to clarify, I fully expect that my initial attempts may only very crudely resemble my intended target. But you gotta start somewhere! :)
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bunnyman666 Profile
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Re: Where to start?


Please note that I have NOT built a masque YET, but have quite a few years of experience in composites. I have built about 30 working bicycles that are still in use as we speak. It doesn't sound like much, but these are 100% HAND BUILT frame sets. I have performed thousands of small repairs in fibreglass and carbon fibre on bike frames, handle bars, and the like. Whilst building for more structural rather than impact resistant properties, the rules are basically the same.

Read EVERY SINGLE RESOURCE POSSIBLE. That is rule 1. Rule 2 is to RE-READ all of the resources. I test, re-test, and test again. Of course there were times that I over-built, then figured out where I could save material to save weight and performance. This is NOT going to be the case in a masque.

The internet is an EXCELLENT resource for all things composite, which is what you will be building with. Yes, the flatter ones are a good place to start, but you have to start some place.

I could go into some exercises to start with, but that would chew bandwidth. If you like, we can continue this conversation via e mail.
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McGuillicuddy Profile
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Re: Where to start?


Thanks for the good information. I'm definitely in the reading, and more reading stage at the moment.

I think I've got the general process nailed down but still have so many questions about the details. Would be eternally grateful to anybody who can add/elaborate/critique anything I have below.

1. Create a face mold using plaster strips and your wife.
• Several tutorials for this:
i. [sign in to see URL]#HeadCast
ii. [sign in to see URL]
iii. [url][sign in to see URL]

2. Create a face plug by pouring plaster into the face mold.
• Anything work better than plaster of paris?
• How to keep the plaster from sticking to the mold? Vaseline?

3. Use modelling clay to build up the face plug to the desired shape of the interior of the mask
• Would really like to see some completed built-up face plugs. Not quite sure what this looks like.
• Presumably you need to build up clay on to the whole face plug, not just the beak/ears etc., to allow for the thickness of foam padding?
• Can I use the same face plug repeatedly, just remove the old clay and start new again?

4. Lay up several layers of fiberglass cloth (saturated with resin), one on top of the other, on to the built-up face plug.
• Would dearly love to see a video of this happening.
•Still so many questions around the particulars of working with fibreglass/resin (any other chemicals required?)
• How large is the sheet typically (20” x 20”?)
• Is it as simple as laying several large sheets one over the other (with resin of course) and getting them to lay flat without bubbles/wrinkles (much easier said than done)?
• What is best way to keep fiberglass from sticking to face plug? Vaseline + Saran Wrap?
• What weight of fiberglass cloth (6oz, 9oz?)
• Anywhere show the proper technique for laying cloth and resin for maskmaking in particular?
• When to use mat vs cloth? Mat is apparently easier to lay up – better for starting mask that won’t be use in a game?

5. Squeegee out as much resin as possible; let dry.

6. Mark eye-holes, vent-holes, strap-slots/button-holes and outside edge of mask with pencil.
• Tricks for symmetry?

7. Drill/cut/trim/file as marked.
• Other than drill, small files, any other must-have tools?

8. Paint/finish.
• Again, not sure of the precise types of materials to use for this, but haven't researched it much either.


Last edited by McGuillicuddy, 3/14/2016, 9:44 am
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bunnyman666 Profile
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Re: Where to start?


Fibreglass (and other composite cloth) is sold by the yard.

Some use a proper mould release to make plugs, others use plastic grocery bags.

Which is where the clay comes in- it helps not only add ridges and other details, but it smooths out the plug.

I hope others will join in.
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McGuillicuddy Profile
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Re: Where to start?


Re cloth size: I meant the actual sheets that are being laid up on the mask. I assume you don't leave the 1 yard sheet intact.

Re others joining in: I hope so too :). It seems we had a thriving community here (which I only checked up on occasionally) up until a year or so ago and things have dried up. Maybe because the Facebook page has taken over?
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Re: Where to start?


Some cloth is 1 yard wide, some is 52" wide. What you would do is to cut the fabric to fit whilst draping over the mould or plug.

One thing to add- you really, really, really do not want the fabric to have been folded, which is why I say to source locally if possible. Folds in the fabric dramatically weaken it.

I always used a stiff bristled composite roller to saturate the cloth. If you use a long-curing epoxy and carefully squeegee excess resin off, you will get a good resin-to-fibre ratio. Of course I would vacuum bag to get all of the excess resin out of the work.
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