My first set of feet were carved from upholstery foam using an
electric carving knife and scissors. They were then painted with
several coats of liquid latex and painted with same. The back has a
wood panel glued into it with Gorilla glue, and there is a threaded
hole. A bolt is used to attach each foot to the stilts, and along
screw driver (that fits into the stilt foot from the back) is used to
screw them in each time.

I don't like my feet. They are rough and funny looking. There are some
guys who can make amazing suits using nothing but carved foam. If you
have ever heard of kr8tiveArts or seen his work then you will see what
can be done. He has done full Predator, Alien, and other suits
(including an awesome Lord of Darkness from Legend) but I just can't
get the hang of foam carving. Maybe a belt sander would help.

My new set of feet, which are in progress along with my new mask, were
sculpted using oil based clay. I have two UltraCal 30 molds (single
piece each since I just sculpted the front). I plan on slip casting
them in latex rubber (a firm grade) and then filling them with soft
urethane foam. I'll paint them with rubber mask paints and glue some
hair onto them. I'm also going to attach some snaps to attach the
bottom of the pants. The screen-used Revenge of the Sith Wookiee suits
also have snaps, and probably the original trilogy Chewie suits, too

Make the claws latex rubber/foam as well. They'll look the same as
ones made out of resin but they'll be cheaper and they will last
longer.

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Matt Pfingsten
Film & Video Editor - Avid/Final Cut Pro/Pro Tools/Steenbeck