Mask

Reference Images 

General Information 

Anatomy & Structure
  1. Chewie's facial structure has more in common with an ape than a dog or bear.
  2. Chewie's teeth are human except for his upper and lower canines, which are sharp, animal-like fangs.
  3. There is a large gap between his upper front teeth and his upper canines, probably to create room for the lower canines when the mouth closes.
  4. The pattern of Chewie's hair radiates from his eyes. He has a mustache-like feature as well.
  5. There are two holes in the back of his mouth, probably for ventilation and/or drinking. A mask with such a feature could allow the wearer to drink through a long straw.
  6. There is a vertical line in his nose and it runs down to his upper lip.
  7. Chewie's eyes are blue.
  8. According to an interview with Stuart Freeborn in Star Wars Insider Issue #70 (pages 40 through 44), the Chewie mask added about 4” (10.16 centimeters) to Peter’s height. Chewie has a large forehead for this reason.
Underskull & Mechanics, Original Trilogy
  1. According to an interview with Stuart Freeborn in Star Wars Insider Issue #70 (pages 40 through 44), the original mask had a polyurethane mechanical under skull. When Peter Mayhew opened his mouth, his jaw would force the mechanical jaws open.
  2. The movement of the mechanical mouth pulled the lips back to reveal the teeth whenever the mouth was opened. In one of the photos of the under skull, you can see a channel cut into the skull that goes from the lip down to the lower jaw in order to facilitate a cable to control the lip motion.
  3. Alternately, Peter Mayhew states that the lip snarl was caused by magnets that repelled each other.
Underskull & Mechanics, Revenge of the Sith
  1. At DragonCon 2007, Peter Mayhew told me that the Revenge of the Sith mask was very heavy due to the animatronics. However, the puppeteer did not use the animatronics much and instead relied on Peter's own movements.
Hair & Skin
  1. Based on behind the scenes photos, Tom Twohy has determined that the original mask was cast in foam latex, also called hot foam. This should not be confused with ordinary latex rubber.
  2. The photos of the unfinished Chewbacca skins (from the collection of Star Wars producer Gary Kurtz) show that the skins did not cover the entire head, but stopped in the middle of the forehead ad in front of the ears.
  3. Darren Blum spoke with Lou Elsey at Celebration III, and she explained that most of the hair on the Episode 3 masks had been glued on using a product called Prosaide. The inner areas of the face had the hair punched in.
  4. The Elsey's also explained that they punched in several hairs going cross-wise to help tame the hair and keep it down against the mask. Darren guessed that they would have punched in a single long hair running ear to ear over the top of the head with it being punched in every inch and a half or so. This hair would be concealed by hair from the face and would give something for the top most layer of hair to bond to using hairspray.
  5. I spoke to Peter Mayhew at DragonCon 2007, and he claimed that the tongue had a small metal rod cast into it that allowed him to make the tongue wiggle. You can see the tongue move slightly at the end of The Empire Strikes Back when he is in the cockpit of the Falcon with Lando.
  6. Peter Mayhew has stated that he had perfect visibility in the masks.

Materials & Construction 

Lifecasting
  1. Bob Kohn’s Life-Casting Tutorial
  2. Amount of BodyDouble Silicone needed
Building a Static Mask
Sculpting
  1. Sculpting detail in oil clay tutorial
  2. Sculpting Neck Detail
Molding

Casting the Skin
  1. Evan Campbell’s Tutorial
  2. How to Seam a Mask
Painting
  1. Latex Mask Painting Demo by Nomad
  2. Nomad's Airbrushing Tutorial
  3. DH2's Latex Mask Painting Tutorial
  4. Vince Hartwell talks about Latex Mask Painting
Building the Underskull
Hair
  1. Julie’s Hair Punching Tutorial
  2. Make Up FX Hair Punching Video
  3. Evan Campbell’s Hair Punching Tutorial
  4. Dan Kurz' Hair Punching Tutorial
  5. HunnyBuns Reborn Supply Hair Rooting Needles
  6. HunnyBuns Reborn Supply Hair Rooting Needles Variety Pack - $14

Building a Moving Mask
Sculpting
  1. Sculpting detail in oil clay tutorial
Molding
  1. Evan Campbell’s mask making tutorial
  2. Mold Making Video
Casting the Skin
  1. Bob Kohn’s Mask Making with DragonSkin & Slacker Tutorial
Painting
  1. Fuse FX Tutorials

FuseFX and Psycho Paints work. You can’t use other pants (even latex mask paints) because they will flake off.

Building the Underskull
  1. Duck’s assembly tutorial
Mouth & Teeth
Hair
  1. Julie’s Hair Punching Tutorial
  2. Make Up FX Hair Punching Video
  3. Evan Campbell’s Hair Punching Tutorial
  4. Dan Kurz' Hair Punching Tutorial
  5. Duck’s instructions for styling the hair

Maintenence
  1. Bob Kohn’s “How to Wash Your Wookiee” tutorial
Officially Licensed Masks