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

[Snarkticon]

Been studying this instructable closely since I plan to make a Horus helmet myself pretty soon. I love your build and the anamatronics are awesome. I just wanted to ask if there was any way to program the servos to move on command? Maybe using flex switches or something similar?

Not that the programmed movement isn't great. I just remember seeing an earlier prototype of yours that used flex switches controlle a MAKE setup and was curious if that was still possible with arduino.

[Honus]

Absolutely! There are all kinds of sensors you could use- bend sensors, force sensitive resistors and capacitive sensors immediately come to mind. What you do is treat the sensor like a potentiometer- the arduino takes the analog input reading from the sensor and maps the servo movement to it.

[Snarkticon]

Very cool. Thanks for the quick response! I'll look into that more once we get to the electronics stage of our build. :)

[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.

[Gixxer85]

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!

[Gixxer85]

Sent you a private message

[Gixxer85]

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.

[Honus]

Good 'ol Teal'c- such a jokester. You definitely won't see me making a Setesh guard helmet anytime soon!

[Ender3D]

Totally awesome!

I don't suppose you've come across other template files for other parts of the costume? such as the gauntlets, (arm bands) boots, and chest plate?

I'd like to throw a complete costume together including chain mail...

[Honus]

I don't have templates for that but have a look over at Jaffa Legions-
http://www.jaffalegions.com/phpBB2/index.php

[Ender3D]

Awesome, thanks!

[Random_Canadian]

Stunning!!! absolutely stunning!!

The complexity and attention to detail in your builds always leaves me... What's the word?... Speechless...

[Honus]

Thank you so much!

[diy_bloke]

I was expecting it to lift off and fly away any moment :-)

[martzsam]

This instructable is so awesome... It must contain...

[Honus]

He was so great in the show- it just wasn't the same after he left. It was always comical when they threw in MacGyver references.

[martzsam]

Indeed. He is such an amazing actor and comedian. Who else could defeat a gould army with just swiss army knife and a wad of bubblegum?

[Honus]

I bet he carried this at all times.

[greybunny]

We got belt bucklets, shoelaces, and a piece of gum... Build a nukler reacter... I'm stuck on a glacier with MACCYVER!!!!

[JoeStrout]

I'm... not... worthy.

You rock. Thanks for taking the time to document and explain it all so well. That multi-layer craft foam construction is brilliant, and I'm pretty sure I'm going to be using that trick on some of my upcoming robots!

[Honus]

Thanks! I think overall it worked out pretty well- getting the surface detail was key to making the helmet look right. I may look at using a hot knife in the future to make marks in the foam sheet.

I look forward to seeing your robots!

[Sethaulton]

Next up you should build the Ancient Environmental Suit. THAT WOULD BE SO AWESOME

[Honus]

That would be cool!

[Gareee]

Great job, Honus. Not sure I have the skills to do the animatronics though.

[Honus]

Sure you do- I've seen your work. If I can do it so can you. :)

[Gareee]

I really have very few electronic skills, other than being able to do simple soldering. But that Horus is too good to not attempt at some point in time.

[Honus]

Soldering is all you need. :)

[Chirpoff]

Congrats on your well-deserved featuredness in the email!!!

[Honus]

Thanks!!

[Monsterguy]

Let's just take a few moments to mourn the loss of Stargate...:(

Great instructable!

[Gunther45]

Very Nice!
but I was expecting it to retract into itself. I kept saying how did they get it to do that. Makes more sense now but very nice.

[Mike44]

awww i miss stargate sg-1!!!!! amazing helmet!

[gomas211]

AWESOME THATS IT INCREDIBLE HOPE YOU WIN THE LASER CONTEST

[miki_cat]

awesome ... i have no words ...

[nancysparkplug]

I couldn't keep my jaw shut while viewing that video.....THAT WAS AWESOME!! I love the original Stargate movie and always wanted to attempt one of the helmets, but it felt a little too ambitious. This is absolutely amazing.

[Honus]

Thanks so much!! I've been wanting to make this for what seems like forever. The whole trick was keeping the cost down while still being able to get all the cool surface detail. Once I had the idea of doing the foam skin there was no going back- I had to do it.

I also had a bet with a co worker that I could have it ready by Halloween (which I lost) but with my three boys being sick and my work schedule I just couldn't get it done in time. I was falling asleep at the kitchen table at 2:00am while testing the electronics- but I was way too excited about this project at that point to pack it in.

Many more late night build sessions and here it is. Finishing this project was a big deal for me. Just wait until you see what the future brings... :)

[fluffydragon]

This.. is.. awesome.

[Honus]

Thanks so much!

[acooper2]

This made me unbelievably happy, to the point that I almost yipped in the lecture hall! lol =]

[Honus]

Thanks so much!- that makes me really happy. :)

[TimberWolf5871]

This is the most awesome thing I've seen on here this month. Is there one for the Anubus headpoece, I wonder.

[Honus]

The Anubis head files are included (which I have not yet built)- the helmet base is the same for both Anubis and Horus.

[blacklion]

Watched video at work. Almost cursed in front of the big boss. This was so freaking cool. You are my new hero. *tear - LOL

[Honus]

Aw shucks!

[jalvarado-3]

I may have missed it, is it wearable?

[Honus]

Absolutely!

[alcurb]

Beautiful work!! I particularly like the detail work and the coloring. Amazing !!
This is Hollywood quality stuff...well... Vancouver B.C. quality stuff.

STARGATE LIVES !!!

[TedMilker]

Where are the patterns located? Did you just go off references or are there template files somewhere that I missed?

[Honus]

The patterns are located at the bottom of step 2.

[TedMilker]

The pepakura files are there but the patterns for the details in this step are not included in the zip file.

[Honus]

Oh- I see. No, there aren't any templates for that- I just eyeballed it.

[dcastor]

Any chance you can post a video of your creation moving?? Would really like to see that.

[Honus]

There's a video of it moving on the first page.

[Sandman.Gor]

I an Fan the serie :P I see all. You working this is very very nice. Congratulations

I working in fiberglass(hobby) I an make 4 pc`s (Casemod), but i dont have working in Arduino, this is amazing!

(ps sorry because off facebook, creat new acount.)

[salexandre]

I an Fan the serie :P I see all. You working this is very very nice. Congratulations

I working in fiberglass(hobby) I an make 4 pc`s (Casemod), but i dont have working in Arduino, this is amazing!

[PeckLauros]

Nice! Thanks to share it with us.

[okoshima]

First off, I'm not a stargate fan... but holy mother of sithis... that is amazing great work

[Skyriam]

As a huge stargate fan, I can only say: OOOOMMMFFFFGGGGGGG!!!!!! This is AWESOME, congratulations. Expecting the "retractable-to-neck" version ;)

[Honus]

Thanks- glad you like it! I don't know about the retractable version- LOL. :)

I have done drawings for an opening staff weapon though- it'll require some different construction techniques as it will see a lot more abuse than the helmet.

[colorex]

Oh, for crying out loud!

Yup, I love Stargate too. I've watched 7 seasons of SG-1 too. It's just amazing!

[Honus]

It is a really fun show. I used to watch it all the time with my first son when he was just a baby and would get up in the middle of the night.

[Eldjotnar]

This is absolutely incredible! I'm definitely going to make one of those.

[Honus]

Thanks! Please do make one and be sure to post pics!

[Kiteman]

Outstanding!

[Honus]

Thank you sir!

[bakunin]

Unreal!

[rkeyzer]

now make it retractable and I pay you for it

[Chirpoff]

That looks *awesome*! Great job on another 'ible, Honus! :D

[adamvan2000]

Dang.... Awesome stuff, dude. Truly epic!

[drknotter]

Oh. Man. I love Stargate! This is fantastic!

[Honus]

Thanks!! Stargate is one of my favorite movies- right up there with Galaxy Quest. :)
I really liked SG-1 too- have every season on DVD.

[iminthebathroom]

wow, WOW - love it - Anubis next maybe?

[Honus]

It would be really cool to have a friend go as Anubis on Halloween! It would also be cool to have both Horus and Anubis guards as Halloween props guarding my front door- they could be motion activated using sensor. Adding sound would be easy too. :)

[bakedicecream]

Dang. No its my turn! :D

[Andib]

It is absolutely beautiful!!! I am still slightly confused about a step or two..but its a wonderful project. I already have the pepakura files. I have never seen anyone use paper mache over it before. I LIKE that! I shall have to give it a try with one of my helmets. I love how yours turned out!

Stunning.

[Honus]

Thanks- glad you like it! I had never seen paper mache either but it made sense to me so I thought I'd give it a go. :)

Reading back over it there are some confusing parts so I need to do some editing. I also forgot a wiring diagram- oops! It's really simple to wire up but I'll get that fixed later today.

[Andib]

Great!!

When you did..add a bit more about adding the foam, please. That bit kind of confused me.

But it is still wonderful!!

A work of art!
:D

[Honus]

Do you mean the foam skin or the foam sprayed on the inside of the helmet?

[Andib]

The foam skin.

The spray I understood. Its skinning the sucker that I got lost. Coudlnt you just cut out pieces of foam like you did the original pattern? I dont see laying foam on top..and 'hacking' it out. Not without losing some major details.

:D

Thanks for the info!!

[Honus]

You could cut foam pieces like the original pattern but then you would have a lot of seams. You want the surface to be as smooth as possible when you go to put in all of the detail lines/grooves with a ballpoint pen.

With every added layer (going from folded cardstock to paper mache/spackling to foam skin) you are trying to smooth the surface and reduce the appearance of the fold lines. The foam skin simply gives you a nice outer layer that has a uniform appearance and allows you to put the detail lines in.

[triforce]

Honus, that is amazing it probably has more detail than the movie prop.

[mikeasaurus]

amazing craftsmanship!

[Honus]

Thanks! I burned an awful lot of midnight oil on this one... :)