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I was wondering if anyone has any suggestions on making a wall panel made of various bones, skulls etc similar to the vacuum formed ones. I was planning on using a 4x8 sheet and glueing various bones, skulls etc and then painting.
 

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Great stuff foam also comes in a black that is used to seal the rocks in ponds. I have seen it used to make small piles of bones mounted on plywood.
Paint the plywood black first then place the bones and foam around them or place them into a area of fresh foam and let set.
What ever you do "WEAR GLOVES" that stuff is sticky to the max and will not come off clothing or skin very easily if at all.
 

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Speak of the devil and he shall appear!

Hi Crin. I did make some skull walls. I made skull molds using Smooth-On products, but you can use store bought foam skulls. If you look at my skull wall picture you'll notice the the profile skulls and the bones are just K-mart props. I cut the store bought skulls in half so I would have to profile skulls to make them stretch a little further.

I used OSB panels. They are heavy, but less smooth so the texture helped a little bit. Plus, they are among the cheapest panels you can get. I slapped the panels on both sides of a frame built with 2x3s. I cut some random holes in the panels on the skull side to give it some depth instead of a flat wall. I used Great Stuff, lots of it, to add to the wall texture and adhere the skulls and bones. I used pink and blue foam scraps to fill in the gaps around the borders of the holes I cut. I need to find some construcion pictures, but here's what 3 of the panels looked like:

 

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Here's a couple of construcion pics:

The first one shows how the hole was cut and the sides of the hole filled in with pink foam that I carved with a Hotwire tool.



The second pic shows how I used Great Stuff to add texture. I would spray the Great Stuff on and pat it down with my hand (using a glove PLEASE).



Hope this helps! Let me know how you make out and feel free to contact me should you have more questions.
 
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