Oh, I'm afraid Emperor Palpatine will be quite operational when your friends arrive.

[Backpacks Got Jets]

http://databank.501st.com/databank/Costuming:SL_palpatine_emperor

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So, kind of disappointingly the Sith Lords detachment is both lacking in direct information and enthusiasm to find answers for the Emperor Palpatine costume so much of it has been personal research to get the right bits and pieces.???? But without further ado... here is my progress on Emperor Palpatine thus far.

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I'll add 1 reply for each item of the build and update those replies as progress is made

[Backpacks Got Jets]

Cane

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[Backpacks Got Jets]

Brooch!

The Emperor is not one to shy away from stylish jewelry.?? Nobody seemed to sell a decent one so I figured I would make it and see how it goes.

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Step 1:?? Clay sculpt.

Step 2:?? Mold

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Step 3:?? Cast

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Casted in Black Resin?? Just gotta shine her up now and she's ready to go

[Backpacks Got Jets]

FACE

To make the scars I can either buy a mask, buy a prosthetic or go completely overboard... i chose completely overboard.

Thanks @Alayfor putting in a bunch of work into this so far.?? Couldn't do any of this without you.

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Boots:

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Boots have been purchased.?? Picture to follow

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Inner/Outer Robes

All fabric is bought.?? Dye is on the way to the house to dye the outer robes Black

Have an awesome seamstress willing to put them together for me once i get myself in gear with them.

[Backpacks Got Jets]

Sith Eyes:

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So this has been a hard one for me to get the right contacts.?? Palpatine is not like Maul or Pre-armor vader.?? He has much more yellow with a thin red band around the eye rather than a red/yellow combination or an eye with a lot of red in it.?? Still looking for the right style.

[Alay]

Scale of 1 to 10 how miserable was getting life cast?

[Backpacks Got Jets]

52 minutes ago, Alay said:

Scale of 1 to 10 how miserable was getting life cast?

it wasn't awful but after a while i was getting super stiff.?? Almost fell asleep a time or two.?? when it came off it was like I had just got done with a workout though.

[Swiftcloud]

That looks messy and fun! I would love to learn how to make casts for masks.

cant wait to see how this comes out!??

[First0rder]

Pretty Amazing and great progress Joe!?? Gonna look Great

[Alay]

30 minutes ago, Swiftcloud said:

That looks messy and fun! I would love to learn how to make casts for masks.

cant wait to see how this comes out!??

The process is more or less as follows:

Prepare the Model:

• Remove any facial hair possible, cut hair short if possible
• Gel down hair as best as possible using a hair gel without alcohol
• Pull a VINYL bald cap over the models head as tight as possible, draw with marker an outline of where it needs to be trimmed
• Cut to the trim line.  Then using denatured alcohol blend to the models head
• Rub down model with release agent cream.?? It has almost a consistency of petroleum jelly.?? Make sure it's rubbed in well especially around the face.
• Place straws into the models nostrils if desired for easier time breathing.
• Walk the model through the expected process.?? Go over hand signals if they need emergency demolding for whatever reason.

Prepare the Materials:

• Pre-measure out 7 or so "layers" worth of the A and B mix for the silicone.?? We used Smooth-On Body Double Standard here.
• Add thickening agent to part A of 3 of the layers.?? We used Thi-vex by Smooth-On for that.
• Pre-cut plaster wraps for the mothermold.?? Take as many as you think you need and double it.
• Lay out mixing cups, supplies, etc.  

Cast in Silicone:

• Starting with a non-thickened layer of silicone, drop it on top of the models head and "pull" it down over their features, trying to keep it even.?? Avoid getting material in their ears at this point, so they can continue to hear for now.
• Using a soft brush, dab into the features of the eyes, nose area, and mouth for full coverage.
• Add more layers of silicone, applying the thickened layers to spots requiring heavier details.
• Finally plug ears with last layer.

Cast??Mothermold:

• Wait for the silicone to cure to a tacky nature at minimum.?? Add petroleum jelly in a light coat over the silicone to act as a release agent.
• Mark a split line as needed for two piece mother mold.?? Add plaster along the back of the head first, being sure to not have any mechanic locking shapes.
• Wait for that to dry, then apply petroleum jelly along the last inch of the mothermold for overlap of front half.
• Apply front of mold, avoiding mechanical lock and overlapping only to the first inch.

Demold:

• Wait for front to dry.?? You'll know it's completely when it no longer feels damp and doesn't throw off heat.
• Remove straws from nose if present.
• Demold front of head first, prying slowly and carefully to not hurt model.
• Demold back half, lay them safely aside.
• Have model make faces, contort face, helping to release silicone from skin.
• Cut along back of silicone along neck vertically and at angles.?? About up to middle of neck.
• Run hand under silicone and along models face to help release.?? Peeling slowly, take hood off model, making sure spots like ears, mouth, and eyes release easily.
• Remove extra materials from model with denatured alcohol.?? They should shower immediately afterwards with soap & water.

[Swiftcloud]

Wow! That is a lot of work. I???m not sure I could get my hair to stand down! Lol

Thabks for the Guide. Maybe I???ll try it soon. ??

im thinking Jar Jar Binks since the actor was also a Best.