NBC Studios -
Burbank, CA |
 My professional association with NBC began in 1985 with a simple call asking me if I
could come in to create a mask at the request of Jim Alvarez, head of the NBC Wardrobe
department in Burbank, CA. I had recently met Jim during an interview and was delighted to
receive the call.
The mask was of the character Lion-O from the Thundercats, a new syndicated cartoon
series for children.
Lion-O became the first of many projects I would produce for NBC over the next several
years. Because of Jim's generous nature, I was able to showcase my talents on everything
from novelty hats for the 'Tonight Show', to giant spiders for 'Punky
Brewster'. I enjoyed
working there very much.
Here is how I created the mask:

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Step one - Developing the PatternThe Pattern for the Mask is
developed over a mannequin form of the human head. By utilizing a custom designed skullcap
the proper control over visual sight-lines and fit are insured. With the features
realized, you can start to bring the character to life.
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Step two - Building the MaskThe pattern is transferred to polyurethane
sheet foam, cut out and keyed in order to duplicate the original model. The pieces are
joined using an industrial strength adhesive. The mask is refined and the contours are
reinforced. |
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Step three - Applying the FinishThe finish is determined by
the original design and may include a variety of techniques. For this mask, a specially
designed paint was used to apply the make-up and skin tone. A custom screened-lens
inserted into each eye completes the effect. |
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Step four - Creating the WigThe unique qualities of polyurethane foam,
allowed for the stylized and elaborate construction of the characters wig design
without adding unnecessary weight to the finished product. The wig was layered over a
foundation base, secured to the skullcap and airbrushed. |

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imago3d@juno.com
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