The process began with a 3D scan of my head done by a vendor. I used that make a 3D print of my face. The hands and boots were also 3D printed, but from downloaded files (other people). To make the torso, I dressed up in old clothes (over painter's coveralls and a wetsuit, just in case) and slathered a low odour 2 part plastic (Smooth-Cast 325) over me, then cut myself out when it hardened. All the items were then glued to the door, gaps were filled with plaster or wood filler as needed. The carbonite texture was made by smearing plaster of paris around the rest of the door. It was then painted with a black basecoat and silver topcoat, and weathered with black paint and wood stain. The thermal detonator was also 3d printed and fitted over a round door knob.