Animated Death Star Hat: Welcome to the Dork Side by lewisb42
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Step 1: Materials and Tools

Materials
  1. Large plastic mixing bowl.  Mine is about 13 inches at the rim and is just barely big enough.  Cruise the cheap dishes aisle at Wal-Mart to find a good one for a buck or two.
  2. Hard hat.  These can be found at Home Depot / Lowe's / etc. in the same area as the safety goggles.
  3. Small Xwing and TIE fighter toys.  Mine came as kid's meal toys at Burger King a few years ago.  Other possibilities:
    • As of this writing, I think the Star Wars Titanium toy line has a set with both of these in it (It's pricey, though, about $30, and is probably heavy)
    • There was a Micro Machines Star Wars line several years back.  They're probably cheap on eBay.
    • If you have a 3D printer, I've seen models on Thingiverse that would work
    • Look for papercraft ("print, cut, and fold") models on the web
  4. Gray spray paint.  Look for the kind that works well on plastic (e.g., Krylon Fusion).
  5. 18-gauge wire
  6. Small 6V gear motor.  I think I used one of these (I don't know for certain because it came as part of a larger kit).  The offset-gearbox turned out to be a big plus.
  7. Some clear acrylic ("Plexiglass").  I used a piece about 16" long by 2" wide by about 1/4" thick.
  8. Battery holder, single "C" cell.
  9. toggle switch
  10. a Dean's plug (optional, but adds some convenience)
  11. wire, 20-gauge stranded
  12. some wood scraps
  13. (4x) small eye hooks (I think these were the smallest available at Home Depot)
  14. small wood or sheet metal screws
Tools
  1. A black Sharpie.
  2. Utility knife
  3. drill
  4. bandsaw
  5. hot glue gun
  6. soldering iron
Kiteman says: Aug 12, 2012. 7:15 PM
Awesome - somebody has got to turn that video clip into an animated gif!

My only suggestion would be to somehow install the batteries within the hat (there looks to be enough space), thus saving that dangling wire.
lewisb42 (author) says: Aug 18, 2012. 7:37 PM
The animated GIF is now available on the intro page. Enjoy!
Kiteman says: Aug 18, 2012. 8:07 PM
Awesome!

(I've spammed it to everybody at HQ!)
lewisb42 (author) says: Aug 19, 2012. 5:43 AM
Wow, thanks!
lewisb42 (author) says: Aug 13, 2012. 4:05 AM
The animated gif is hopefully forthcoming. :)

It has enough space inside to stuff the battery in there. The wire is nice in that I can turn it on and off without removing the hat.
lewisb42 (author) says: Aug 18, 2012. 6:54 PM
Update:

Took kiteman and Jayefuu's advice and consolidated the switch and battery pack into the helmet. The switch is now located in the back of the helmet near the bottom rim and the battery pack is mounted on the underside of the top of the helmet.

Also discovered that the motor I used can accept a screw into the center of the output shaft, similar to how arms are mounted on servo shafts and held in place with a small screw. Used that and a oddball screw with a wide flat head to reinforce the helicopter blades and keep them from popping off the shaft.
mikeasaurus says: Aug 13, 2012. 12:50 PM
This is my new favourite Instructable!
Jayefuu says: Aug 13, 2012. 7:34 AM
This is fantastic! Though I'm with kiteman, batteries and switch in the helmet, if you know where the switch is, near the rim, you shouldn't have to take the hat off.

Oh and I like the pun in the title, stellar work ;)
lewisb42 (author) says: Aug 13, 2012. 8:02 AM
I may have to bend to peer pressure on this one. :) I've another project that has priority between now and Dragon*Con, but if I have a free evening I'll take your suggestion.
Jayefuu says: Aug 13, 2012. 8:12 AM
Next year you should do R2D2. Paint the bowl like R2D2 and make the bowl spin back and forth slowly with a servo. Add a few blinking LEDs and some chirping noises.
lewisb42 (author) says: Aug 13, 2012. 8:19 AM
OMG YES!!!
Jayefuu says: Aug 13, 2012. 8:29 AM
Get on it! You still have 2 weeks until Dragon*Con. Then whoever you're going with can look as awesome as you, plus you can get another featured instructable :p

I wish I could go to Dragon*Con, Brandon Sanderson's meant to be reading another excerpt from A Memory of Light. (due January)
lewisb42 (author) says: Aug 13, 2012. 10:35 AM
If my mini-sumo 'bot gets ready before then I may try!

I'm kicking myself now because I used to have a large snack-bowl with an R2D2 design that would have been perfect -- especially since my artistic skills are...less than stellar. Sadly, a couple of moves later and it's long-gone...
zomfibame says: Aug 13, 2012. 5:47 AM
Nice hat!
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