Head is up for sale.
My two attempts at getting it moulded up to make a fibreglass one that could be modified have been very costly, both in time and money. So I'm flogging it on to someone with a smaller noggin, who can make use of it, and the money from the sale will go to my friend JD who has made a larger vacformed one that I'm pretty sure will fit me with no problems.
This head is typical of Threepio costuming in general: there are so few people making parts that the size stays the same - I'm fortunate that my neck, chest, arms and legs are pretty much the right size and don't put a lot of weight on. All my physical obstacles come from a skull that has a slightly wide pair of cheekbones (damn my photogenic mug!) and a bit of a belly. I hardly drink at all now, don't eat bread, and I'm back to avoiding pizzas and takeaways. If only there were more than two people working on larger head shells - so far Northern Ireland and Brazil are my only options! Hardly ideal to try before you buy!
Body wise, I've now prepped the upper arms (biceps) to a stage where I'm happy to get them chromed. Of course, I won't get them done separately, they'll all be done in one hit, but as far as smooth surfaces go, they're amazing.
I've received the forearms back from the model shop and they've all had a good thick coat of 2 pack primer on them which will need sanding down to match the same glass-smooth surface that the biceps have.
The Back is great now - rear box 'lid'; had been detached, inner lip and shelf fitted, and all given a nice coat of primer too. The purpose of the inner shelf is to mount the voice kit, batteries and hopefully a speaker into. This way, the helper/spotter can switch the systems on and off easily and at the right time.
The next thing that I plan to do is do some Dremel work on the hands - separating the finger shells and priming them. As soon as they're all done I might go for chroming them in advance, just so I can attach them to the gloves, and thus complete the hands totally. NOTE TO SELF: Got hand rods, I still need 'knuckle studs'.
So a lot of sanding coming up. Then, at looooong last, I might be able to put the entire thing on for a test fitting, sans head of course.
Personally, I hate that it's taken such a long time to progress , but as I've said before, it's because I have no work space and very little free time. I have so much to do, day to day (day job, CJS stuff, kids, acting etc) but now things are progressing with help from my mates and of course the amazing guys at the model shop who have helped me so much. Thanks for bearing with me.