The Batmobile Replica

 

Movie clips:

the Wing (8.3M)

 
   
   
  When the blueprints had been derived from scale toy models, they were projected onto large sheets of paper that were applied to styrofoam blocks. The main shapes were sawed out with a band saw. Sculpting then began with a custom made tool made from the middle part of a regular saw.
When the basic shape was there, the work to get a smooth surface started, that involved sanding plaster that were applied to the styrofoam. This proved to be extremely tedious work and took most of the production time. To test and adjust the methods used, work began on the canopy, which is a separete piece.

After the sculpt is completed and painted, it's time to make moulds from it. The moulding process starts with figuring out where to split the mould so it can be taken apart. This mould consists of 62 pieces! For each seam a plane has to be in place to be able to assemble the entire mould.
Once the mould is done at has to be prepared for casting which involves covering up the seams with special clay and then wax it enough so that the mould won't get stuck to the body surface.
The wings proved to be particularly tricky to cast since they're so thin. It's impossible to reach to the end of them, so they had to be split across their length.

One of the hardest parts of a project like this is to achieve symmetry and for that templates has to be made to compare the left and right side.

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(The videos requires quicktime from apple.)

  
 

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