Animatronic Stargate helmet

I love the movie Stargate and when I first saw it I immediately knew I wanted to make one of the super cool Horus guard helmets. I had sketched multiple designs over the years and figured out several different methods for building it but rejected them all for one reason or another- usually due to cost or complexity of construction. Since I wanted this to be a costume helmet my requirements were that it be light weight, comfortable, have decent outward vision and be reasonably durable. I also wanted it to be buildable by anyone using simple hand tools. Most important of all I wanted it to move in a similar fashion to the movie helmets.

All of this proved to be a pretty tall order but eventually it all came together and now you can make a moving Stargate helmet of your own!

Here's a video of the helmet-



Be sure to click on the photos to download high res images.

Step 1: Tools and materials

Tools-
Saw for cutting wood/metal- I use a Milwaukee hand saw that accepts reciprocating saw blades- super handy! http://www.homedepot.com/h_d1/N-5yc1v/R-202525764/h_d2/ProductDisplay?langId=-1&storeId=10051&catalogId=10053
Cordless drill w/ various drill bits
X-Acto knife with #11 blades
Scissors- small sharp scissors make cutting the patterns easier
Glue gun
Sandpaper- small piece of 100 grit to smooth wood edges and spackling
Allen wrenches- Inch
Screwdrivers- phillips and flat head
Soldering iron
Ballpoint pen
Bench vise or some other way of securing work while cutting metals
Trusty Instructables multitool- I never leave home without it!

Materials-
Cardstock (2pkgs)- http://shop.hobbylobby.com/store/item.aspx?ItemId=168038
Newspaper
Craft foam sheet (10ea 12" x 18")-  http://shop.hobbylobby.com/store/item.aspx?ItemId=160137
White glue
Tacky glue-  http://shop.hobbylobby.com/products/clear-gel-tacky-glue-163972/
Gorilla glue-  http://www.homedepot.com/h_d1/N-5yc1v/R-100141832/h_d2/ProductDisplay?langId=-1&storeId=10051&catalogId=10053
Spray foam-  http://www.homedepot.com/h_d1/N-5yc1v/R-100068117/h_d2/ProductDisplay?langId=-1&storeId=10051&catalogId=10053
Paint- 1 can silver
          1 can copper
          1 can satin clear coat
Pastels- dark blue, reddish brown, black
Spackling paste- http://www.homedepot.com/h_d1/N-5yc1v/R-202314762/h_d2/ProductDisplay?langId=-1&storeId=10051&catalogId=10053
Plywood- 3/32" thickness,  6" x 12" (3ea)- http://www.micromark.com/Birch-Plywood-3and32-Inch-Thick-x-6-Inches-Wide-x-12-Inches-Long,6909.html
Minwax Polycrylic sealer- http://www.homedepot.com/h_d1/N-5yc1v/R-202061439/h_d2/ProductDisplay?langId=-1&storeId=10051&catalogId=10053
Velcro- http://www.homedepot.com/h_d1/N-5yc1v/R-202261913/h_d2/ProductDisplay?langId=-1&storeId=10051&catalogId=10053
Cotton swabs/ soft brush- for applying pastels

Electronics/Hardware-
Arduino- I used my own design Arduino servo board (you can use any variety Arduino you want- available at RadioShack, Sparkfun, Adafruit, etc.)-  http://www.instructables.com/id/Arduino-animatronics-make-your-awesome-costumes-m/
Small switch (2ea)- http://www.sparkfun.com/products/8837
JST female connector- http://www.sparkfun.com/products/9749
JST extension wire http://www.sparkfun.com/products/8670
AA batteries (4ea)
AA battery holder- http://www.sparkfun.com/products/552
Servos- Hitec HS-81 (3ea)- http://www.servocity.com/html/hs-81_micro.html
             Hitec HS- 425BB (2ea)- http://www.servocity.com/html/hs-425bb_super_sport_bb.html
Servo extension wire- http://www.servocity.com/html/12__servo_extensions.html
Gears- 22T 32 pitch Hitec splined (2ea)- http://www.servocity.com/html/32_pitch_hitec_servo_gears.html
            24T 32 pitch 1/4" shaft mount (4ea)- http://www.servocity.com/html/32_pitch_plain_bore_gears.html
4-40 Swivel ball links (4ea)- http://www.servocity.com/html/4-40x3_16__nylon.html
4-40 threaded rod- http://www.servocity.com/html/threaded_rod.html
Super Duty short control horns (2ea)- http://www.servocity.com/html/306sh_short_single_horn.html
Servo shaft adapter 1/4"- http://www.servocity.com/html/servo_shaft_attachment___250__.html
10-32 Rod end- http://www.markwilliams.com/detail.aspx?ID=1313
10-32 tap & drill bit
10-32 bolt
10-32 nuts (3ea)
1" Aluminum angle- http://www.onlinemetals.com/merchant.cfm?pid=971&step=4&showunits=inches&id=62&top_cat=60
Nylon spacers- 1/4" ID x 1/2" OD- http://www.servocity.com/html/_4_nylon_spacer.html
1/4" OD brass tubing- http://www.onlinemetals.com/merchant.cfm?pid=1539&step=4&showunits=inches&id=84&top_cat=0
3/8" Aluminum rod http://www.onlinemetals.com/merchant.cfm?pid=1082&step=4&showunits=inches&id=195&top_cat=60
Aluminum mounting hubs w/bolts-  1/4" and 3/8" bore http://www.servocity.com/html/set_screw_hubs.html
10mm super bright white LEDs-  local supplier or http://www.cablesandconnectors.com/30000-30.HTM
10mm LED holders (2ea) I purchased these locally but I found some online here- http://shop.vetcosurplus.com/catalog/product_info.php?cPath=376&products_id=9026
Resistors- 100 Ohm (2ea) -local Radio Shack
Standoffs- I used standoffs I salvaged from electronics equipmentI found in dumpsters but lots of places sell them online in various sizes -http://www.servocity.com/html/standoffs___spacers.html      
Female breakaway headers- http://www.sparkfun.com/products/115
Miscellaneous wire/small wood screws
Small piece of steel sheet- I used a scrap piece cut from old electronics chassis material
Magnet- http://www.kjmagnetics.com/proddetail.asp?prod=DA2

Comments

[werethebrudes]

If anyone can build me one of these and the quality is top notch in functionality and aesthetics I will pay top dollar for one. Thanks Honus for sharing!

[dmichaels1]

I can understand your older method of attaching the head, but this got WAY too technical for me here. As I see it you have 2 servos for left/right.The third servo spins/tilts the head. Do you not have an up/down?

I haven't even begun working with electronics, but I'm looking to make a "simple" (at least I thought when I started) moving head such as this for my first project, but I can't wrap my head around this page's assembly.

[Honus]

It's actually very simple. When both of the servos move forward the head moves up. When both of the servos move backward the head moves down. When one servo moves forward and the other moves back the head will turn (while tilting slightly.) The third servo tilts the head. Make sense?

[babymonkeystuff]

a great book for the construction part of the project :
Papier-Mache Monsters by Dan Reeder. He has a web site GourmetPaperMache.com
His construction method is very durable. Fast construction.

[zgsx]

awesome ! cant wait to see your next project ! im sure it will be EPIC !

hmm. in that case, 3 servo then. more natural fluid movement. err. Can you make me head mechanism ? i dont have access to most of the stuff in my country.

[Honus]

Where are you located? If you can't get the materials shipped to you I'm sure I could make the mechanism for you. It might be a while as I have a pretty big backlog of work at the moment.

Sorry for the late reply!

[zgsx]

Sent you a private message

[zgsx]

The details is insane ! i love it ! as a stargate fan, this is a to-die-for-prop . anyway, wanted to ask is it possible to make the head moves with just two servo and move according to where ur head is moving (ur predetor helm,gun thingy is a good example) ... still new to microcontrollers :)

[Honus]

Thanks! I'll have another really cool Stargate project later this year. :)

You could make the helmet move using only two servos- just have it move up/down/left/right and leave out the tilt servo. Having it move in a head tracking fashion is much more difficult because your head really can't move inside the helmet.

[white dragon]

AMAZING! ive never seen a better how-to helmet than this. its simply AMAZING...

[Honus]

Thanks!!

[MyCustoms]

This is phenomenal, your attention to detail is breath-taking.

[Honus]

Thanks!!

[MyCustoms]

Dude this is pretty hardcore!!!!!!!!!!

[poofrabbit]

Congratulations on being a finalist in the Halloween contest!!! Can’t wait to see if you win! Good luck!

[scoochmaroo]

This is insanely good, even without the bonus Arduino work. Really stunning, and inspiring. I may be hitting you up for advice when I get to the Arduino phase of my current costume project. . . which *might* be done in time for next Halloween?

[Honus]

Thanks so much! Whatever you need just let me know- I'm happy to help. Making costumes is a year round endeavor for me as well. :)

[AnubisAndIsis]

Whoah! What a piece of work!

[Honus]

Thanks!

[navyman001]

i dont have the time or skill to try and make something like this being in the navy and all i was wondering would you be willing to make one for sell?

[Honus]

I've got three big projects in the works right now but I would certainly love to do a kit with all of the animatronic parts. Vac forming the helmet pieces would also make construction go a lot faster. It would take some work to make the master patterns but I think it could be done.

[nerd1701]

nice job! Surprising its made of paper. You should try these techniques to make a serpent guard helmet.

[DouglasG1]

You should build the serpent guard helmet.

[furthuron]

this thing is AWESOME!!! i want one bad now! very well made and great looking.
thanks for this ible, makes me realize maybe i could make some things like this i have always wanted.

[Honus]

Thanks!

[judahtravis]

My god you're brilliant.

[AdielFernandez]

Hey there, I usually dont comment, but this is a fantastic build. Everything about it is top notch, from artistry to gadgetry.

I was most impressed by the head movement. When I saw the video I actually gasped when I saw the falcon head move. Its amazing that you could so accurately recreate bird like movements using only left to right movement plus rotation from the micro servo.

Definitely one of my favorite Instructables. Brilliant!

[Honus]

Thanks so much!! Wait until you see the costume projects I'm working on now... :)

[sypher]

If I gave you one, could I borrow this to make a vacuum mold off of it?

[Honus]

Gave one what?

[BC_Jeffro]

update
ears mocked up still working on gears using Lego and craft foam board
still haven't made the face

[Honus]

Awesome!

[suuun]

just awesome.

[Honus]

Thanks!

[BC_Jeffro]

im in the middle of my build im going to do the Anubis version still waiting on some more parts, i can only hope mine is half as nice as your final product.

here are some other projects me and my girlfriend have built thanks to people like you and this great website.

[Honus]

That is awesome work! Make sure to post pics when you're finished with the Anubis head. :)

[Steamfunk]

Pick up your phone; it's Rick Baker. He wants schedule a time to bow before you. Great job!

[Prototyp 81]

A+ great job!

[Honus]

Thanks!

[bobsir]

Fantastic artwork! And now, for a Jaffa joke:

A Serpent Guard, a Horus Guard and a Setesh Guard meet on a neutral planet. It is a tense moment. The Serpent Guard's eyes glow, the Horus Guard's beak glistens, the Setesh Guard's... nose drips.