Now that I had the base foundation of the Darkness head piece made, I could start putting things together. As stated in the earlier section, Miles and his crew had a metal attachment for the horns inside the socket. I wasn't too sure how to pull that off. What I did was to insert the horns and play with the positioning until I liked where they sat. Once comfortable with the look, I needed to work on building up the headpiece so the sockets "flowed" more naturally to the skull piece. I trimmed large chunks of foam and attached with duct tape. Once I liked the shape, I placed thin strips of duct tape to bridge the gaps and smooth things out. I also placed a strip of foam as a ridge for his head.
I couldn't help but think that at this stage it looked like a Rebel pilot helmet from Star Wars.
Here is where more fiberglass comes into play. Now that I had a solid foundation, I cut fiberglass cloth into strips and attached to the headpiece.
The epoxy resin was applied and allowed to dry. I used only one layer here as it was already attached to the skull piece and fairly sturdy.
As you can see in the above photo, I marked the sockets about 3 inched down to be trimmed. Once the desired length, I inserted the horns and held them into position with pieces of foam.
Oh yeah! Lookin' good!
I permanently attached them with 3 inch wood screw through the top of the sockets. (No one will be able to see them from that angle anyway!)
Now I needed to make the ridge where the horns and the sockets meet as they did on the movie costume. I did this by attaching a thin strip of foam all the way around the leading edge where the horn and socket meet. Small strips of fiberglass cloth were then attached and finally covered in the resin and left to harden.
Once the fiberglass cured I sanded down any rough spots.
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