This will be where his "teeth" go but where you will see out of. I cut out the shape of Lego Batman's mouth. To do that I used foam core building up areas. Since Lego Batman wears a cowl, I had to create the illusion there was an interior head with the cowl over the top. Using foam core I created shapes to make Lego Batman's head 3D. Now that said, I'm all for you using a ruler or a tape measure, as a matter of fact I would encourage you to do so, I get get impatient, it's a flaw I know, lol. I get driven crazy by silly things like measuring. In reality what you are doing right now is creating an additive sculpture. To make this happen I took a handy dandy sharpie looked at a picture of a Lego Batman on-line and drew on the areas I knew I would have to build up. The Lego Batman head is really what helps sell the Lego Batman Costume.įirst you are going to need to build up the armature for his face. Now, you could use caulking to achieve the same look, but I had hot glue and I didn't want to add any more weight to the head then I had to. This technique will be used a lot during this project. This method should be done on the exterior as well as the interior. This lets the glue cool down and gives more of a light layer. I then used a scrap piece of cardboard (or foam core) and used it like a pallet knife or putty knife to move the hot glue up towards the Styrofoam and fill in the cracks. To help seal any openings, I placed hot glue on the cardboard tube, near the Styrofoam but not actually on it. I know, I know I said no hot glue.but there is a time and place for hot glue and now is the time. I laid a few books on top of my Styrofoam disk to help add pressure so the glue suck well to the Styrofoam wreath and disk. There is also a Styrofoam glue out there, I've not tried it but if you wanted to give it a try to hook the two Styrofoam parts together you could. Even a low temp hot glue gun can cause the Styrofoam to be "eaten" It's not that it can't be pulled off, but for this part it really is best to use gorilla glue. You might ask, why not hot glue Poof? Great question. Since this is Lego batman he doesn't have that issue because he has his happy cowl that goes over his head. If you wanted to make a Lego head you could use another smaller Styrofoam disk to put on top for the little Lego nub. You will notice that it's starting to get a Lego look and feel. Again you can use Gorilla glue to glue this on. Once dry you can add the 10" round Styrofoam disk at the top of the head close it up. Put something under the area you are working to save yourself some clean up. It should be noted that gorilla glue is really sticky and slightly messy, It does sort of foam, so put the glue on, add some pressure and go do something else. In retrospect, I wish I had also gotten a 10" ring to put at the bottom of the head to make a neck. This added a little height as well as comfort.
Once cut, I took two 12" Styrofoam wreath forms and glued them with gorilla glue to the top and bottom of the head. I cut the tub down 12 inches, so it was taller than my actual head. You can find this as Lowes, Menards, Home Depo or any store that sells similar building stuff.
To Create the basic Lego head shape I used a 12" heavy cardboard tube used to put in cement poles.