When the Mouse came to us and told us what they wanted a giant
hat that sat directly on the 'rocking face' on the front of S-World, We
told them how involved it would be to rebalance the whole head and install
bigger motors to handle the weight increase. We then suggested making a
stationary hat that the hat could rock beneath. They went for it and the
following day, we're on the roof of SW measuring the head for a hat!
We built a precise mock-up of the head out of plywood paneling.
We made it so it could pivot on a plate we bolted to the wall. After ascertaining
an approximate size we cut a rough hat out of foam and tailored the inside
to allow for the movement of the hat.Once satisfied with the inside,
I finished sculpting the outside with a surform, wire scoops &
brushes, and several kinds of knives.
Then I applied a thickened, low-catalyst coat of polyester resin over
it, after that coat was tacky I applied a 1/8" coat of fiberglas and a
smooth finish coat to it. The piece was then glassed to an aluminium frame,
painted and hoisted into place.
