Armature

In this section I'll show how I build a Styrofoam armature.  The correct name for this structure is really a "buck".  This technique is used extensively in the automotive industry to make mock-ups of cars.  An armature is really more of a framework, a buck is a near net shape form.  There are many advantages to using this system.  First is probably weight.  If this form was all clay, it would weigh a couple of hundred pounds.  This would mean building a very substantial steel armature to support that weight.  Cost is another factor.  Styrofoam is much cheaper than oil based clay, which is what I use for modeling.  The third reason is that this is how I like to do things and since I'm The Boss, that's how it's done around here.

The Styrofoam patterns have been cut, a simple steel armature has been welded to a steel base and the stacking begins.   I have grouped the patterns so I could have less cutting to do.  The steps will later be cut down later. 

A little higher and a front shot.  So far I have about 8 hours invested in this step from layout to here.

The Styrofoam all in place.

This is a photo to give an idea of scale.  That's Cindy who works around here sometimes.   The next step is to begin to smooth the form.  I do this using traditional carving techniques.  First I use a very sharp knife to rough out the form.  Next comes work with a rasp.  Finally, I use sandpaper.  Styrofoam is very easy to work, so this goes fast.  It took about 6 hours to finish 6 hours to finish out.

This is a shot of the form that has been carved and rasped.  The beak is a problem area since the Styrofoam is very delicate.  I'll work that down with sandpaper.

Here is the final Styrofoam form.  The beak was a little tricky and I had some patching to do.

Hot wax is applied to to form so clay will stick.  Without this step it is almost impossible to get clay or wax to stick in the modeling phase.  I use my foundry wax blend.  I imagine beeswax or paraffin would work too.  The wax also makes the armature stronger.

I've finished the wax and moved upstairs to my studio to start modeling.  The two pipes are to stabilize the form so I could move it.  The bottom is so thin, it's a little unstable.  I'll use them throughout so I don't break the delicate Styrofoam.   Now it's on to modeling.

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