Using Jessie’s maquette as a guide it was professionally scanned. Then slices of heavy duty polystyrene was cut to the shape of Pat and then glued together in layers.  Pat then had to be filed, sawed and shaved into shape. Next came a coat of kerabond and Isolastic. After this rendalock was bolted onto the entire surface and this was followed by another coat of kerabond and Isolastic. Four workshops with five people in each workshop.

Slices copied from the maquette and glued together

Polystyrene is very messy

The smoothed version of Pat

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Once the rendalock was bolted into place, Pat became very heavy.