A short while back I received a lovely B pull Thomas helmet from L.E. Props. Daft Punk's helmets have long been on my personal to-make list, so this was rather exciting for me. First step, trim the casting! This was done using a Dremel cutting wheel and sanding drum as well as sandpaper and spot putty.
The ear pucks were mounted with 2 ton epoxy and the whole helmet was primed. The annoying part of this build was creating the visor, which I unfortunately didn't document. Basically, 3/8 PETG sheet was cut to the exact size of the visor frame and heated with a heat gun until it fit evenly. The inside was sprayed with a light coat of Rustoleum lens tint to make it shaded.
Next thing I did was create a template for the hand plates. I made these scaled to my Mt. Everest sized hands, but they're available for download if you want to try your hand at it yourself! (Hah, punny)
32 pieces were cut out of 2 mm styrene with an exacto knife, then each piece was heated for 10 seconds with a heat gun and shaped to give it a curve. I found it very useful to have sharpie around so I could press the side to each piece while it was hot to give it a nice even curve.
Each piece was then sprayed with a couple coats of shiny spray paint.
To mount the hand plates onto gloves, I put gloves on and placed a dab of high temp hot glue onto the center of each piece, then placed each piece one by one in the correct position. I think weatherstrip adhesive would have been the way to go instead of hot glue, but I wanted to be Thomas at a party the same night. Much impatience, wow. The whole process of making the gloves took less than three hours.
For the lights in the helmet, I ordered a bunch of pre-wired LED's from LighthouseLEDs and got a strip of pre-wired red LEDs from Radio Shack. I threw together a couple ugly housing units out of styrene and colored tissue paper and just hoped that it wouldn't look too ugly from behind the tinted visor.
With everything wired up, I mounted the lights to the inside of the helmet using epoxy putty, threw on a leather jacket, and it was time to party!
I should mention the lights blink too! Next thing to do is learn arduino...
And getting snapchats like these in the morning is the best.
Thanks for reading!