How to sculpt from Sculpey to Casting: Mr. Jimmies – The Zombie Doughnut (Process)

Greetings! Here is a slideshow that gives a peek into how this little Zed Doughnut was built.
Grab a beverage, then flip though and see how I work. So lets go…

1. And we’re off! Start with aluminum wire and some smaller steal thread wire to hold it together. I use standard 1/8 inch wire found in most hobby stores. The smaller steal thread wire helps the clay (super sculpey) stick to the wire skeleton.
2. Aluminum foil is used to bulk up the body of the doughnut. This saves sculpey and keeps the final sculpt lighter. Again, I wrap everything with super fine steal wire to give the sculpey something to cling to.
3. The fun begins! Adding sculpey to the skeleton.
4. Just adding clay here. Roughing out the base and the dough. I use one box of Super Sculpey, with one small block of regular white and one half block of black. When throughly mixed this creates an excellent grey. Super sculpey is an odd translucent pink, this makes it hard to see fine detail like troublesome fingerprints! The white + black adds opacity and a handy middle grey tone.
5. Shoe detail! Why wouldn’t a zed doughnut wear chucks? The small details were added with various sculpting sticks. The knurled front tread on the shoes was made by rolling the chuck from an x-acto knife around the edge.
6. This is after 3 baking sessions. I baked him at 275 degrees for 15 minutes after the base doughnut and standing base were done. In addition, I baked after each leg was completed: 275 degrees for 15 minutes. And let the sculpt cool down naturally while still in the oven… this prevents cracks. Then I began working the right arm…
7. The entire Zed is baked at this point except for for the frosting. This frees me up to try different patterns on the frosting and everything else is locked down.
8. I’m melting!!! Happy with the “frosting” I apply mineral spirits with a soft brush to smooth the finish.
9. GET ME OUT OF HERE!!! Baking the Zed at 275 degrees for 15 minutes. AGAIN!
10. Super fine sandpaper… Mr. Jimmie the zombie doughnut is not happy.
11. Polishing my Zombie Doughnut with a dremel…(don’t judge)
12. Taking the finished sculpt out for a spin. Time to add sprinkles!
13. Sprinkles!
14. The Sculpey original is done, so now I take it to a casting company and get resin blanks made. This is the first one, with an apple for scale.
15. Washing the blanks in preparation for primer.
16. Automotive primer is excellent! Allows the paint to adhere to the resin.
17. Multiple resins in the wild…
18. Using an Airbrush with thinned acrylic paint for the pink base.
19. Some fine detail on them shoes!
20. Almost done with a green Zoughnut!
21. A completed pink “Mr. Jimmies the Zoughnut”

I am now in talks with a local studio here in Albuquerque, Fire Wheel Casting. There will be 25 limited edition Mr. Jimmies made, some blank and a small batch hand painted by me. It’s looking like the run will be produced by June. Just in time for the Albuquerque Comic Expo! Stop back soon for updates…
Till next time. ~ John
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