Restoration of WOODY from Toy Story - CRAZY Zombie edition

Full restoration of Sheriff Woody from Toy Story. I will repair this crazy Zombie edition of the beloved doll from the classic movie Toy Story 2 from the year of 1999.

The restores tool chest that I use in this video
In this video, I use an almost identical copy of the famous restore tool chest used in the original movie Toy Story 2 produced by Pixar animation studios back in 1999. I got this tool chest from another very skilled woodworker and YouTuber named Matthew Moustache. You can see him create the beautiful tool chest here:

• Making Toy Story 2 Cleaner Tool Chest...

The restoration process
I started disassembling the Woody doll by taking off all his clothes. One foot was really burned, so I had to use the heat blower to get off his cowboy boots. I took the Zombie head off and placed it on a looking home build platform which is a reference to one of Sid Phillips's toys from the original Toy Story 2 movie.

I pulled out all the U nails and the metal plate that was melted into Woody's head. I did a short sandblasting and I used baking soda as sandblasting media to avoid destroying the soft plastic on his head. I cleaned all the holes and made some reinforcements with wood and tiny nails, so I could sculpt a new strong, and lasting face with clay. I used air-drying silky doll clay to sculpt and repair Woody's face.

I used a lot of time filling, grinding, and shaping the face. I painted him using my airbrush with many layers of acrylic water-based hobby paint. I mixed a custom skin color that is slightly darker than the original color and I also painted his hair and eyebrows a bit darker than the original Woody. I printed the eye color with my color printer and glued the paper onto his eyes.

Buzz Lightyear made a new cowboy belt buckle for his friend. And this ended up really cool. I washed all his clothes in my mini washing machine and bought some second-hand boots on eBay to replace to old burned ones.

It was a very challenging restoration and a hard job making the face look real again. I was aiming for the face shape and cool expression that Woody has in Toy Story 2 movie. And I think that I succeeded very well with the face repair job.