"You Killed Kenny" Door Stopper

Ever since I bought my first bag of sugru (check out this link if you don't know what it is), I've used it for a lot of stuff (fixed my bike, improved a pen, made a custom handle to carry bottle crates or made my shoes more comfortable ...), but for this Instructable I wanted to make something bigger.

In order to exchange room air fast and efficient, I like to open my windows entirely. The problem is, that if I forget to close a door, it slams shut.
Door stoppers are pretty handy, but either boring or expensive. So why not make one?

For those of you that don't know who Kenny is, check out the wikipedia article:
http://en.wikipedia.org/wiki/Kenny_McCormick

If you don't like South Park how about Mario?
http://www.examiner.com/images/blog/wysiwyg/image/Mario_Dead.jpg

My brother saw the door stopper and asked me to make one for himself with his head. Hopefully I can talk him out of it, else I will for sure post the result.

Material

• orange and black sugru, there are three options (EDIT: when I wrote this Instructable, sugru didn't exist in the colour red... Now you can buy it in their shop. I will leave this part, because it shows you how to get colours, that are not available. Apparently their is no more orange sugru. You can get it by mixing red and yellow)
  • use sugru only for the legs and boots, you will need one pack each and orange and red paint.
  • cover the whole body with sugru, you will need about three (5g) bags of orange sugru (you may need more, depending on how sparingly you apply it), one pack of black sugru and red paint for the blood.
  • cover the whole body and make red sugru for the blood, you will need 4 bags of orange sugru, one pack of black sugru and red silicone pigment or colour as well as disposable gloves.
• flesh, white, brown and black paint, paint brush
• rubber floor mat, the thinner the better
• wooden door stopper (or just a piece of wood, check step 3)
• wooden ball Ø about 8cm - 9cm (if you can't find one check out the next step)
• Apoxie Sculpt or any type of modelling clay
• sand paper
• strong glue

Tools

• a saw, files (If you decide to work with wood)
• modelling tools (not really necessary but will make modelling easier)
• box cutter

I couldn't find a wooden ball in the right size, so I covered an eight cm styrofoam ball with modelling clay.
Make two stencils, one with an eight cm and one with a six cm hole and mark the lines as shown in the pictures.
Use the lines as a guideline to model the head. Remember to flatten the back of the head as shown in the last picture, to give it a better stand. Sand paper will give it a nice finish.

You can either make the body entirely out of modelling clay or use wood like I did for extra rigidity.
As you can see in the second picture, my legs are 6 cm broad. You can of course use your own measurements. The whole body is about 8 cm long and will later be extended with sugru.

I couldn't find a mat without a structure, so I had to cut it away with a box cutter.
You can either make a stencil out of paper or cut the outline freehanded.
If you don't want to make red sugru skip the next step, cover the mat with a thin layer of Apoxie Sculpt and paint the blood stain red.

To make red sugru you should wear disposable gloves. You don't need much colour to stain the sugru, just use small amounts and keep mixing them.

Use water to make the applying easier and to smooth the surface.

Now you will have to paint all the parts, that you don't want to cover with sugru. You might ask why sugru and not for example orange Apoxie Sculpt. First of all it is flexible, I'm living in a rented flat and I don't want to damage the doors. Second it has a great grip, I've parquet floor and the wooden door stopper never worked well at all and third it is very easy to apply.
Glue the body onto the mat, the only body parts for which you should really use sugru are the legs and boots, everything else can simply be painted.
Start with the orange sugru, let it dry and apply the black sugru (you will have some left, think of a way how to use it before you start, in order not to waste it). Make the outline of the jacket out of a thin string of black sugru, as well as the cords from the hood. Glue the head onto the mat and body, congratulations you made it!

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