Food for discussion! Thanks Brian!
vaderman wrote:
I think to discuss the origins of this Return of the Jedi we need to start from the beginning........
1. Sculpting the clay mask over the plaster head of Dave Prowse.
2.When the clay mask was finished in a last minute discussion it was decided that a chin vent should be incorporated so that Dave could breathe easier.
3. It was decided that I would just put a line in the clay and the vent would be cut out by the plasters in the fibreglass stage.
This is terrific to know. Thanks for mentioning that. So then you are saying that your ROTJ mask (which is like a TM mask or possibly also like a VP mask), has the same chin vent inscription as you did on the original sculpture? Although the final chin vent outline would then presumably match perfectly the inscribed chin vent line, I would think. What you are seeing might either be that line, or the remnant of the original screen vent that had been cut out, but then as you mentioned, filled in for later molding. I would think it is the latter.
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4. After the faceplate was moulded and cast in plaster I sharpened the faceplate up with carving tools but just left the line of the chin vent as it was.
Also very interesting...and makes perfect sense.
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5. There were 2 screen masks with the chin vents cut out and taken to a finish which were kept in a box (locked at all times in the wardrobe dept when not on stage - where they were supervised by 'Mother')
How the chin vents were cut should actually be slightly different, especially on the corners. But among all the authentic castings there only seems to be one kind of vent, identical to the mask that appears onscreen.
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6. I believe a third mask was cast and used by the special effects dept to work out any issues.
Also interesting...wish we could see either the 2nd or 3rd mask in some form or another...
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I don't know when a mould was made or even where it was made for ESB but there are 2 options - it either came from the third mask where the chin vent was left in but it would have had the tusks applied and the clips on the top or it was a screen mask and the chin vent was filled in with clay and the line of the chin vent put in before it was moulded. It would also have the tusks and clips.
Yes I think it was the latter, well almost certain of that.
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I believe that this is the mould used on ESB. I'm told by the sculptors on the ESB production that they did no work on the mask or helmet and therefore the plasterers must have made the alteration to the front of the helmet to create the ESB look.
This is very interesting as well to have confirmed and is consistent with what we see with castings like the Paul Allen and TM ESB...
If only the plasterers continued that tradition of not making any alterations to the Vader mask/helmet for ROTJ/ROTS.
) but possibly instead of getting out of the hobby just have a wee break and come back to it when you feel your lifestyle allows.
as u might want to call them in the community...some even work for well known collectible companys 
but it's all about names. Have a name? You're almost untouchable.
