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Has anyone tried filling a latex mask with spray foam to make a prop head?

11858 Views 14 Replies 11 Participants Last post by  Kev730
I'd like to make a zombie puppet (like this) for next year and have been searching for a good mask to use as the base. Has anyone tried filling a latex mask up with spray foam (expanding foam) or had success with it? I'd like to the mouth to be able to be opened and closed so it could be "eating" the wearer.

Thanks for your thoughts!
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I've filled whole head masks with Great Stuff numbers of times, but the faces are static (even if the prop isn't). I developed a method that works well for me --Simple, no mixing, no brushing, costs <2 bucks to do a mask.
I tape over any holes and fill any protruding features first. Once they set, I give the mask a little spray of water and do a shallow coating of the entire inside and let that set. If I want the head just as-is, I water-spray again, put a partially-inflated balloon in, and fill around it with the spray foam. The balloon will offer less resistance to expansion than will the already-set layers of foam, so there's no distortion. It stays light-weight and you can do several masks with a single can of foam. If I want to adapt it later to a body form, the inside will be hollow, which offers multiple possible attachment methods. If I want the mask-head to go on a mannequin or a frame, I tape a crumpled wad of newspaper in the center and stick a length of 1" PVC pipe inside the mask from the top of the head to the "neck", sticking out a few inches. Then I foam it in, making sure the PVC stays at the angle I want. Again, the crumpled newspaper takes up some of the expansion (not as efficiently as a balloon, but I've had no trouble), but I make sure the pipe's cemented in well.
When it's done, the PVC can be trimmed. I slide the pipe that's in the head down over a dowel I've put in the neck of the mannequin or body form, making the mask-heads easily interchangeable. A hole and a cotter pin can keep the filled head from turning if that's an issue, but sometimes, as with the Spider Hill zombie, slight head turning is an advantage.
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