This Instructable describes how I did things - often I made it up as I went and you should do the same!
Soldering iron (optional)
Drill Press , 3/4" bit , small 1/32" bit
Carving knife / tools
Pins, Sewing machine, tape measure
1 x Roll of black duct tape (of course)
1 x sheet of Poster Board
Cardboard (old boxes)
Flour, water mixed to pancake batter consistency
Translucent plastic to cover the eyes
Light Up Eyes:
Wire, 2 LED lights, 9 volt battery, 9v connector, resistor ,
7’ of Rope / strong string,
5 inches of your pvc pipe for jaw hinge
2x Home Depot paint stirrers
3 x 10’ ¾ diameter pvc pipe
4 x 90 degree couplings, 4 x 45 degree couplings, 2 x T coupling
Salvaged closet organizer supports or similar
A mess-o-Home Depot 5 Gallon paint stir-sticks
Hunk of wood (I glued 2 ¾” thick pieces of scrap together, I think it’s tight grained pine)
Copper wire (From Romex house wiring)
10' of Rope
Bunch of bargain fabric (I had close to 8 yards of a 60” fabric, could have used more)
Alternative, black plastic table cloth
Window screen for a view port
Step 1: The Head - Getting the Shape
We are creating a face that will be mounted on a frame, not an entire head. Instead of starting with a beach ball or some other solid support I started with the form and then built the support structure into it.
1. Fold the poster board in half across the long dimension. I taped a couple edges to make sure both halves stayed aligned.
2. Draw half of your face design.
3. Draw in perpendicular lines at the corners and at points along curves to define tabs that would be folded back and connected.
5. Carefully fold back tabs and lightly tape to create the start of your 3D face.
I stopped at this point. I wanted to understand my frame and how the face would attach before building the internal structure.