So, I decided to go with the original method used in Disneyland, which probably turned out to be a good thing, since Disney's "internal projection, when viewed through the semi-opaque head, was not as bright as traditional projection from outside, and the facial features seemed to distort somewhat, as the natural shadows from the contours of the head form were eliminated via the technology. Therefore, the external video projection was restored to Leota in October 2001."
Fine with me, it turned out to be much easier this way, and the hiding the projector problem could be solved by building a shelf on the inside of my fence, covered in ivy.
You can kind of get an idea of where it went here, that big box in the foreground, directly in front of the crystal ball (
pic).
So then I needed the projection "screen," for the Madame, a crystal ball with a blank head inside. Conveniently, I had purchased a Gemmy Spirit Ball at the clearance last year, and was able to removethe head from within it to have a big, empty sphere with a nice little base.
Start with this:

pop off a leg, and unscrew the...screw to release the globe, which twists off

Then unscrew everything else. This is tricky, if you want to save the head for later projects
Now, for the head form itself, I tested the projection (which I found
somewhere online (possibly through this site of HalloweenForum?)) on a standard wighead, and found it to be distorted in the lower half of the face; Ms. Thomas's jaw is wider than the wighead's. So, I coated the entire wighead in a thin coat of plaster, and made the lower face bigger. Then, I sanded it a smooth as I could (this is a little tricky, as the plaster tends to flake off if it's to thin).
I think the trick with the head is to not make it too rounded-- the flatter it is, the less the image will distort. Also not that there are no lips-- I sanded these off of the wighead before plastering to ensire that Leota could speak without mouth distortion.
I projected the image onto the form, and made a few pencil marks of the hairline. I didn't find any wig I liked, so I made her hair out of spider webbing hot glued to the head.
The head was attached to the globe base using hot glued stacks of foam core scraps. You can see that the head isn't very pretty up close, but it didn't make much difference in the final product.
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