These super cool props were made for the reality TV show Great American Road Trip. Seven Presidents in all: Washington, Kennedy, Nixon, Reagan, Bush, Clinton & Obama.
They were CNC milled out of foam with a light weight, climbing helmet Gorilla glued to the foam. The producers were very specific on the weight of these Bobble Heads and of course the likeness had to be dead on - no pun intended for half of them.
We usually hard coat foam for durability but as stated the added weight was an issue. This was 1lb foam so they were a little sensitive to the touch, unprotected without the hard coat. But they only needed them strong enough for 6 hours. All were primed the foam with Kilz water-based primer and then we airbrushed the faces.
We have larger CNC milling machines now & could produce them faster & with more detail although maybe not cheaper than before.