Working with MDM Props, we made this metal sculpture for Alaska Alaska and Disney which is displayed at the Royal College of Art in London England. For more information including an article by Vogue magazine about the project, see here:
First the shape of the body pieces were cut out of styrofoam and coated with plaster to keep it strong. Grooves were cut out for the metal wire to sit in.
The wire was bent by hand or with simple tools and checked against the inner mold.
The filler in the head was removed and the cross sections of the body were welded on to support the weight of the head. It was then attached.
The arms were attached and the cross sections were filled in.
The rest of the filler was then removed and any missing pieces were attached.
Adding final touches including filing down welds.
It then went to get sprayed.