Introduction: Astronaut Costume
Finalist in the
Autodesk Employee Halloween Contest
I love space. So I decided to make a space suit** for halloween. It was super fun to make, and relatively inexpensive.
I was able to make it out of things I had lying around from old projects. I imagine that if any maker-type wants to put this together, that already has a stock of supplies will only have to spend 20 or so dollars to complete this project.
**NOTE: NOT FOR ACTUAL USE IN OUTER-SPACE
Step 1: Gather Materials
- Wood Glue
- Really round balloon (available at party stores)
- Wood Filler
- 9V Battery
- 9V Battery Clip
- Hot Glue Sticks
- White Acrylic Paint
- Silver Spray Paint
- Painter Suit
- White Satin
- Silver Lame
- Hot Glue Sticks
- Stir Stick
- Razor Blade
- Sand Paper (80 Grit and 150 Grit)
- Soldering Iron
- Wire Snips
- Wire Strippers
- Paint Brush
- Sewing Machine
- Glue Gun
Step 2: Blow Up Balloon, Mix Glue, and Cut Strips.
If you are using wood glue, you can use a 1:1 ration of water to glue, and coat your paper strips with them before you apply them to the balloon.
Step 3: Paper Mache!
There are lots of really good Instructables on how to paper mache, after a little research I believed I was ready to begin. I dipped each strip into my gluey water and then applied it to the balloon. I think I ended up applying six layers of paper, and it took....... a long time.
When I was done applying the strips, I made a slightly thicker glue/water solution and brushed it over the entire surface of the sphere.
Then, walk away. This guy took two days to dry.
Using a razorblade, I pierced the balloon. I cut a hole big enough for my head, and then separated the balloon from the paper.i
Step 5: Fill, Sand, and Paint!
After the helmet had been fit, I had to remove some of the large wrinkles from the sphere - so I used some wood filler! I sanded the entire sphere with 80 grit sandpaper so that the wood-filler would bond to the sphere.
Again, wearing gloves, I squeezed the wood filler from the tube and smoothed it into the cracks. It took about two hours to dry.
I then re-sanded the entire helmet with 150 grit sand paper.
Step 6: Painting and Cutting.
I painted the outside of the helmet with white acrylic paint. It took about 30 minutes to dry.
I then traced out a basic shape around the sphere that would be the helmet's opening. Using the razor blade, I cut the opening out.
Using some bailing wire, and some masking tape, I reinforced the cut edge of the helmet, so that it wouldn't slump on my head. I then sprayed the inside of the sphere with silver spray paint.
Step 7: Add LEDs to the Helmet.
I plugged in the hot glue gun, and the soldering iron.
I soldered 4 LEDs to eachother, in preparation to make parralel series that could be powered by a 9V battery. Then, I glued down the LED series, and ran wires all through the helmet to one PCB.
I plugged in a 9V battery, and it worked! Onto the suit!
Step 8: The Suit!
This part is pretty fun. It's great because I was able to imagine whatever I wanted to put on to the suit. I based it of a really big painters suit that was about 8 bucks from the hardware store.
I made up some elbow and knee patches out of silver lame and interfacing, making rippled waves with the sewing machine, then cleaning up the edges with a serger. I had to open the legs and the arms of the suit to sew down the patches.
Step 9: Go to Space.
I realized that the more bulky this suit looked, and the more panels I added the more authentic it seemed. I want to grow the costume to be appropriate for other festivals and events where I could sport an astronaut costume.
I paired the suit with my super busted snowboard boots, and they looked great. The paper suits are a bit flimsy, but a great base for this costume.
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