Dressform Trial 2A

Darcy and I attempted once again doing the cast in two different parts (back first, then front). The good news is that I did not pass out this time! Considering that two 8"X180" packages of casting only covered about one layer, I got twice as much. This time, I shopped at Hobby Lobby. They had the same product for a little bit less.

Others that have built dressforms by this process recommend doing four layers; however, one layer of gauze gets really hard as long as you do not move too much. My thoughts were to get the cast thick and hard enough to hold its shape to sew together, and then I would add casting over the dried layers and seams to create a sturdy cast to fill with polyurethane foam. Darcy casted two layers all around with a little extra to support curvier areas. I still had plenty left to cover my cast after sewing both pieces together!

If you would like to try this, here is the process I used:

1) If you are casting two separate pieces as we did this time around, you do not need the medical scissors I mentioned before. What you will need is a marker, petroleum jelly, undergarments you don't mind throwing away, plaster gauze (at least four packages of 8"X180"), scissors (just in case you need to cut smaller pieces), bowl of water, rags to wipe off petroleum jelly, two chairs of the same height, and a large drop cloth. This time around, we set up a mirror so I could watch what was going on. It significantly made time seem to go by much faster than last time.



2) Use the marker to make a line or dashed line down you side. This way, you can apply the casting up to that line to create two pieces that will fit together properly.

3) This is the gooiest part! Lather up with your petroleum jelly…including your undergarments. Make sure that your hair is tied up and off of your neck! Position chairs at a comfortable distance to rest your arms on, making sure there is enough space to cast under them.

4) We started by casting the least curvy half first. We did the first layer with the small pieces (about 4"X4"). The smaller pieces help capture your curviest parts and seem to be easier/faster to work with. Make sure to overlap these a little or else the cast will not be sturdy. The second layer, we used larger pieces (about 4"X8") criss-crossing them. It doesn't take too long for the cast to get hard and hold its shape. After the last piece of last layer is applied, it should take 10-20 minutes to become hard enough to take off.



5) Wait at least overnight for the casts to finish drying before sewing them together. You will need a thick needle and heavy duty thread. Match up curves, arms, hips, etc. and start sewing.



6) I'm not sure if you can tell from the pictures but the sides came together somewhat at an angle instead of a nice curve like a whole-body cast would create. If this happens, stuff the cast to create the round curves the form should have. While stuffed, cast two layers over the seams to hold the shape you want. After the sides have dried, apply at least one more layer of casting around the entire form with the stuffing out.



Marty, my fiancé, does taxidermy so he has some old two part polyurethane expanding foam left from making molds. We tried it out yesterday, and though it's old, it still works just fine. Therefore, I will be filling the cast next!