Finally! It took me four horns to make one I was satisfied with. Jeez laweez. I've been working on this project for weeks. I learned a lot during the process, so the next horn I sculpt will take infinitely less time.

---WHAT IS IT?---
This is the master positive for a mold I'm going to make to make some horns. Mirepoix needs two orange horns. I sculpted this with a long base so I can cut it at angles to fit either side of my head. I'm planning on trying to make other colors and mount them to headbands to see if they'll sell. Think I'll have any takers?

---HOW'D YA DO IT?---
I glued two pieces of blue styrofoam insulation together, then roughed the shape with rasps and sand paper. I sealed my foam with casting resin and smeared a layer of resin filler (Bondo, essentially) onto it. Cue a shitload of sanding, primer layers, filling, more primer layers, more filler, more sanding, more primer, etc. etc. This process has been detailed by other people elsewhere, but I'll talk about it more if you have any questions.

Anywho, I got it super shiny by going up to 1200 grit sandpaper, then buffing it with some green buffing compound and a microfiber towel by hand. I finished it off with some turtle wax. In this image, you can see that the surface isn't totally perfect, but I am hoping that the turtle wax will help seal it enough so my silicone won't pick the scratches up too badly. From five feet away nobody can see 'em.

---PRODUCTS USED---
- Blue styrofoam insulation (the same as the pink stuff)
- Gorilla glue (This stuff expands like crazy, remember to clamp it with some tape!)
- Smooth Cast 325 (Two layers over my foam to seal it)
- 3M All-Purpose filler (Cheaper than bondo, works fine.)
- Rust-Oleum Automotive Primer (I should have bought some high build stuff, too. Woulda made my life easier. Black was a bad choice, too).
- Turtle Wax (It's in the garage; I don't feel like standing up to double check what the hell it actually is. It's car wax.)
- Lots of sandpaper. Lots. Tons.
- Green buffing compound (It came in a cheap pack of rotary tool bits I bought from Harbor Freight... It was green, that's all I can tell you).

Most of what I know I know from reading the Volpin Props blog. He does a really good job of detailing his processes (which are much fancier than mine!) http://volpinprops.blogspot.com/

Ask questions, I'll answer 'em!