[Interview with Tom McLaughlin, part I of II]


Most people who work with silicone, know the name Tom McLaughlin.

His book Silicone Arts is considered by many to be the bible for working with these materials.

If you don't know Tom yourself, I can tell you that he is one of the nicest, most giving people that I have ever met. If you ever have the pleasure of speaking with him, you will leave the conversation not only wiser, but you will have gained a life long friend.

This interview was conducted during a recent trip to LA at his home.

aRvin:I guess I’d like to start off talking about your recent projects. I know You were in Tiajuana
for a while...

Tom: Oh, that ate up every ounce of my strength, and time... yes I set up... It had nothing to do with silicone. Except for some of our proofs, and masters. But we ran a lot of foamed latex. Setting up a factory there that ordinarily does slip cast work to do foam as well. The molds were very new to them because they were used to a big hole on their molds to fill with latex... these were closed. Two piece molds, and they had to learn how to duplicate them, I think we peaked at three mold sets for each a day. A front and a back for each. I think we could have pushed ourselves to 5 or 6, but I didn’t have a whip <laughs>

aRvin So what was the project for?

Tom: It was for Rubies Costumes. They are the biggest maker of Halloween gear in the world, and they are in the process of designing a range now for 2002 release, so I think things will be at the spring shows.

aRvin: Oh cool. Has there been anything else in the works recently for you?

Tom: I’m working on the new Silicone Arts book, and the film world has kinda dried up. I don’t know what to think about that anymore. I’m putting my feelers out and diversifying. I’m doing some work with some private clients, which I’m having a great time with, I’m doing some prototypes for people who invent things. Making things for them in rubber, so they can go and drum some cash up to have it made as a commercial thing.

aRvin: Would you like to talk a bit about the new edition of the book?

Tom: I can if you want. There’s going to be photographs... lots and lots of photographs. And more information on how to use silicone as a casting medium, as well as molds. I’m going to go into molds and see how many different variations there are, because every shop makes their molds in their own way...

aRvin: When can we look forward to the release of the book?

Tom: Well, we’re aiming for the spring of 2002, we hope, we hope we hope <smiles>

aRvin: and that's going to coincide with a large silicone extravaganza...

Tom: We’re going to do another silicone extravaganza, and see if we can top the last ones that we gave... yeah. We’re going to do it on the east coast. There are some people that live closer to the east coast that wouldn’t come out to California for the things we had at UCLA. So that will be fun.

aRvin: So taking a bit of a step back, what were some of the early influences that got you into the industry

Tom: Oh...the Universal Monsters, of course. I found out at an early age through a book or magazine (it might have been Look or Time Magazine) that they made the monster’s faces out of rubber. Liquid latex. And that set me going. I had to track this stuff down. But if I knew about silicone when I was 9 years old I wouldn’t have gone near latex.

aRvin: <laughs>

Tom: I wouldn’t have...my goodness I found out over the years that you can push the materials with plasticizers and vary the rate of cure, and polymerization and make rubber or plastic softer or harder then it was meant to be or provided to you as. You can only push latex so far before it either cracks, or falls to pieces on the firm end, or turns to gunky gluey glop at the soft end. But with silicone you have so many more consistencies that you can pull from the one polymer. Its like the difference between the range of leathers. Soft medium and hard leathers, and then going up from variable gels in silicone all the way up to hard soles of your shoe kind of rubber.

aRvin: What were some of the earliest projects you worked on?

Tom: lets see.. I entered in this whole thing from a perspective as a puppet maker. I was into makeup, but never considered it a profession that I wanted to go after. I liked being involved in more of a production because a puppet production is usually smaller then a full scale film. So you can do a lot more. You can do lights, and sound as well as the make up and stuff. I did props and stuff for films at the out set. There is this place on the east coast..Robert Joyce. He’s out here now. Oh he made some wonderful props for a pirate film that was being shot out in the Caribbean. We used a lot of polyurethane's and stuff...Oh! At Robert’s ship I helped to make a pair of K.I.S.S boots for their 76 tour. Out of polyurethane. They kept falling apart, but that wasn’t my problem. I wasn’t out on tour with them. But at this place we made all of the props for the pirate film. Bones, and coins and... oh you name it! The works. All period stuff. We finished the work, and we went our own ways. In a week or two’s time we had a call back to see if we could make a whole other set of props in less then a weeks time to send out on location. It seems that the location folks were from New York and presumed that the seasons of the year are the same al around the planet... and they weren’t. It was monsoon season where they were shooting and the entire set, and all of the props and everything they brought out there got washed out to sea. So we got called in to make a whole other set of props in a weeks time.

<Both Megan and I laugh quite a bit about this>

aRvin: Wow. That's a fun little production schedule you had there.

Tom: Yes. You have to plan a head and make a few phone calls.

aRvin: after your stint with Robert Joyce what did you do?

Tom: Oh, Lemme see. There is a story if you really want to hear it. I used to do puppet shows myself and had a troupe of 7 or 8 of us, and over a 3 year period we did close to 300 shows. We linked up with the county parks, and did about 75 shows each summer in a little sweat box. It was a trailer with a hole cut in the side. And boy did I lose weight then! And then I worked with Bill Baird in Greenwich Village on Barrow Street. He had a marionette theater in his basement, and storage room. It was 5 floors high. He lived on the fourth floor, and the top floor was the work shop. He was an eccentric. A lover of the filthy limerick.

<Megan and I chuckle again a bit>

Tom: He started out in vaudeville, went to live television. He invented the auto prompt. He called it the scriptanola. It was a long roll of paper with all the lines for the play rolling in front of your eyes. Hanging over a bar doing a marionette with both hands, who’s going to hold your script?

<more chuckling>

aRvin: Yeah, that’s true.

Tom: Yeah, he taught me all sorts of fun things. He was the first person to use latex and latex foam for a puppet in films and TV. It was such a hush hush thing at that time. He’d make molds and send the molds out to be filled with foam latex, and he didn’t really have a look at how the process went but he’d been doing lots of slip cast work before that. That’s where I got a really good shot of trying some foam out. Then I moved on to the Muppets! They were doing the muppet show and needed to duplicate Miss Piggy because she was a star and they only lasted about a year before they’re worn out. And they found that no matter how hard they tried they couldn’t carve a piece of poly foam to look the same twice by hand (which is how they had been making them until then). There’s a lot of the characters that they had were fabricated from sheet foam and patterned and glued and tucked and trimmed and they make a shape, but Miss Piggy is a complex shape that was actually carved by hand out of a piece of poly foam.

aRvin: I thought she was actually a sculpted...

Tom: No, the very first ones were carved by hand and then she became a minor icon in her own right. She had to be a few places at the same time in New York and London, being photographed for calendars in Paris so they had to have a few of her that looked exactly the same so they started to mold and cast them in foam and foam latex and that’s where I first worked with Dick Smith. I’d been on the phone to Dick Smith prior to that, and I think that’s the first time I actually met the man. He was called in to help us to help us get off the ground with the foam. He taught us all of the rules that were set up here out in California for running prosthetic foam. And as soon as he was out the door we went and had to break all the rules, because we weren’t making foam appliances, we were doing pigs. I think the very first Miss Piggy foam cast was a solid piece of foam latex because we didn’t make a core for it. Somebody snipped the inside of it out over the course of a week to find out that this wasn’t the way to go.

aRvin: wow

tom:<laughs> No one had done that before; we hadn’t a clue!

aRvin: right. So how much foam would that have taken?

Tom: about 2 quarts, and it shrunk like hell. The thicker your piece of foam, the more it’s going to shrink. If it’s an even thickness all the way around it’ll shrink at an even rate. It’s the same thing with dried prunes and pears and apples.

aRvin: Back then in your early days of foam, what kind of volumes were you getting with that?

Tom: We were using the Schram stuff which is was what Charlie passed on before he himself passed on. We couldn’t get more than a 5 volume rise, I don’t think. Certainly no more than 6, but averaged a 4. Hadn’t a clue we could push it to a 7,8,9, or 10 at that point, it would take another few years of running foam to find those things out. Had some old timers on the phone, though who wore fishing boots to work.

aRvin: Fishing boots.

Tom: Fishing boots! They were making foam latex filling up huge mattress sized molds. If the stuff didn’t set up, they’d have to get in there and scoop it all out and clean the mold out. It was more an art than a science. They hadn’t a clue; if it would work one week, the following week it wouldn’t.

aRvin: so how long did you end up working with the Hensons?

Tom: On and off I’ve been involved with them for 17 years. It was a good long stretch at the start - it might’ve been 6 or 7 to 8 years and the Dark Crystal itself involved me for a good 4 years with them. From the concept and the early r and d all the way through to moving to England to actually build the film.

aRvin: Do you have any particular fun stories from that period?

Tom: Jim was having some of his people go through the patent office and see what had been done and patented before. He paid for some blue prints of some pretty bizarre and strange and weird devices that people thought were worth investing all this money into patenting it. One of them was no more than a scheme where you tied a string around your neck and around each arm and leg and dangled them from on high to move a puppet down below, and that was patented. They took that person’s money! That’s on file. I don’t know what the number is...

<chuckling from all>

Tom: It was bizarre stuff. There was a good ole team of 10 or 12 of us that started out on the east coast with Brian Froud living there working with the core team, the r and d team, and was very fond of going through the trash, Brian was. Outside of seafood places, for all the seashells and bits and pieces and crusty animal bones. He’d bring them back to the shop and clean them with bleach and work them into his designs. We were looking for a very organic look and feel.

aRvin: After the Dark Crystal, didn’t you do work on some of the Star Wars films?

Tom: Yes, right after the Dark Crystal, they overlapped at one point, it was just a point where I had two or three films that were booked ahead of each other, and I had to pull out of one and slide into the other. I did the last two of the first three. [Star Wars films] Which were in the middle of Star Wars, which still doesn’t make sense. And you were talking to Steve [Prouty] before, about the Star Wars films..do you know how hard it was not to tell anybody that Darth Vader was Luke Skywalker’s father? I didn’t even tell my mother!

<laughter ensues>

Tom: My girlfriend didn’t even know!

aRvin: Wait..he’s his what???

Tom: <laughter> Darth who?

aRvin: So what kinds of stuff did you do on those films?

Tom: All of the foam pieces made in the UK . there are some things like the pig guards and admiral Akbar that were made in California, but the rest of the stuff we did there. All the Jabba the hutt foam, bib fortuna, the guy with the tentacles around the side of his neck. That was Mike Carter I think it was. He was the guy who got eaten on the stairs, er the escalator in American Werewolf in London. He did the sales pitch to the Star Wars guys “Hey I have extensive experience with prosthetics.” Little did he know that he was going to be made up from head to toe in foam. The only thing you saw that was his was the tip of his nose and his lips. Everything else was foam, and he was miserable. And contact lenses.
The [Rick] Baker film, [American Werewolf] was a two to three day shoot. This was weeks.

aRvin: Were you running all the foam on Empire Strikes Back?

Tom: Yes! I was kind of let down with what they’d done with the shop, what they’d done with the Darth Vader reveal. He was a tired old man, it was such a build up. The sheer villainy of the character you kind of expected something with bugs and things crawling out and tentacles, but it worked. From what I remember it was done very quick like it was an afterthought because I don’t think Stuart Freeborn knew it was coming till the very last minute.

aRvin: I can imagine the makeup being much more extensive.

Tom: So we had days to pull that together. So much foam and working so late...

TO BE CONTINUED!