Skull Respirator: Fabrication

I am using the same Jello™ mold that I used for the anemone canisters to make the top part of the skull. I first cast polyester resin into the aluminum mold which had been sprayed with a mold release. Then I bandsawed the skull in half, and sanded it down somewhat more until the shape looked right sitting atop the existing skull.



After pondering how to make this respirator look less organic and more mechanical I am thinking I need to fabricate the entire skull, and not use any of the original plastic skull.

Above you can see a bunch of acrylic pieces that I've cut out with the laser, ready to assemble. As you might imagine this takes quite a bit of planning and taking measurements from the original skull, to get to this point.

Here are the same parts assembled. I will mold these and cast them in resin to modify. Then I'll add on the gear teeth, and the lower jaw.