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This Instructable will detail the process of creating your very own Thomas Bangalter Daft Punk helmet. While this tutorial may seem specific to Thomas Bangalter's helmet in particular, there are many processes involved within that will be helpful to anyone looking to get into prototype making as well as some electronic work.

A few caveats beforehand: While the methods I employ here were able to furnish me with a finished helmet, I am in no way saying these are absolutes! In the end, the best processes to follow are those which you are most comfortable working with, so if there is something here that seems easier to do in your own way, by all means feel free to modify the process to your preferred flavor of building.

I should also note that this is a complicated and lengthy process. The final result took me a little over 4 months to realize, so anyone looking to follow a similar path, be prepared to be in it for the long haul! That said, this is only my second helmet project. If you're more familiar with electronics, casting, moldmaking, or just plain have more freetime than me, your results may vary. This project encompasses elements of sculpting, mold making, casting, soldering, electronic design, and lots of good-old-fashioned sanding.

I am entering this Instructable in the 4th Epilog Challenge because, as you will see, having a laser cutter for some steps in this process would greatly improve the productivity speed! I am an amateur propmaker by trade and, more recently, profession - having a laser cutter to expand the capabilities of my studio would allow for a whole wealth of new opportunities.

Step 1: Blueprinting and Scaling

Blueprinting:
Before I begin any project, I spend a lot of time scouring online for reference images. The gents from Daft Punk are a fairly elusive couple, and to add to the complexity of sourcing references, there have been a multitude of changes to their helmets over the course of their career.

I try to find as many images from profile and portrait views as possible before beginning my blueprints. These illustrations form the basis of my projects, and are designed in Adobe Illustrator. Dimensions such as the overhead view can be extrapolated from two other viewpoints. (pic 1 & 2)

In the end, the blueprints I designed are an amalgamation of many of the changes to Thomas' helmet over the course of its evolution. Whether you decide to adhere strictly to the subject material or base your designs off of personal interpretation, reference blueprints are essential! These will keep you on track and make sure all elements of your project stay consistent and accurate during the course of your build.

Scaling:
In order to scale these blueprints correctly, I open the blueprints in Illustrator, then import a picture of the wearer's head next to a ruler. After scaling the picture appropriately to the ruler's marked dimensions so that the scale of the person's head is 1:1, the blueprints are scaled and printed accordingly. (pic 4)

While this may not be the most precise measurement, I find that it works fairly well with some practice. Often times you may have to take into account lens distortion or other factors depending on how the reference image was shot.

When printing a blueprint, I usually print three copies: one at 105%, one at 100% and one at 95% - these are all compared when printed fullscale to see which one has the best "feel" as a full image. Sometimes seeing the print just slightly larger or smaller can help determine what looks best.

A while ago my Dad rescued a roll-fed plotter from the dumpster of a local school and it now lives as my blueprinting machine. If this isn't an option, you can either try a local print shop, or scale your blueprints with registration marks to fit on normal sized paper. (pic 5)
how do you see through it?
Can I pay 100 dollars for you to build it
<p>They cost 25k for a complete one.... </p>
<p>do you sell or offer a pre assembled visor kit, or know where one can be acquired for those with little electronics experience?</p>
<p><strong>For the silicone Rebound 25 do you think I could get away with just using 2 of the trial kit or would I need the full gallon kit?!</strong></p><p><strong><br></strong></p><p>http://www.smooth-on.com/Rebound%3D-Self-Th/c1132/index.html?catdepth=1</p>
<p>why is it punk?? </p><p>Looks like a startrek/pick a sci-fi helmut, but not punk.</p><p>It is quite awesome though!</p>
<p>daft punk is the name of the musician. </p>
<p>AHA, </p><p>I see, I could not imagine how that was &quot;punk&quot; then I did as two suggested and followed tghe links, plus I wiki'd it. The outfit was a gimmick to sell music. Well it worked for KISS why not someone else. </p><p>great work making the thing, but pointless unless you are making a movie, or going to a party, (for a while anyway). I carve and have made quite a number of useless pieces. Chach-ki's (Yiddish for dust collectors)</p><p>Again, wonderfully done</p><p>thanks</p>
<p>But the reason that they wear the helmets was to remain anonymous and be recognized for their music.</p>
<p><a href="https://en.wikipedia.org/wiki/Daft_Punk">https://en.wikipedia.org/wiki/Daft_Punk</a></p>
<p>Thank you for all the insight on this build. Building this from scratch was very fulfilling,....tough but sooo worth it! Guy Man is next :)</p>
<p>Hi, what an excellent instructable! A mix of electronics and props... A lot of hard work has clearly gone into this project. </p><p>Karl</p>
<p>In oddly crazed digression - say you were to do this for the head/face of a friend and make a mask of them and sneak into a pumpkin patch early in the season and have the pumpkin grow into the mask. Remove the mask and you have the face of your friend as a freak of nature.</p>
<p>I'm speechless now! :D Awesome!</p>
<p>What a craftsmanship! This is incredible! Congratulations on it. Maybe I will try it one day. Just astonishing!</p>
<p>Now I just need the dietary supplements to get my head inside comfortably :) Some kind of phat burner.</p>
<p>How much did it cost to chrome your helmet?</p>
<p>I have the same question. Spray painting with &quot;chrome&quot; paint is not the same as chroming.</p>
<p>Well Mathew, you can get the chrome paint at your local AutoZone for around 10 to 20 bucks.</p>
<p>oh...WOW WOW WOWWWWWW! SUPER JOB!!!!</p>
<p>I wish I had received this email 4 months ago lol. I just bought a Thomas one off eBay and a Guy one from Etsy</p>
<p>though I should add these were premade molds that may not fit my head and there's no LEDs.. I wish I had the right money to blow on Volpin's products</p>
<p>Have you had anyone buy one from you yet, volpin? I wish I had the money.</p>
<p>Can you see out of this?</p>
<p>Greatly detailed work, I wish I had the skills to do this project. Do you sell them? If so how much.?</p>
<p>He takes 25k for a fully finished one.</p><p>See my more detailed answer to lukesjette.</p>
<p>oh...WOW! I wish I could afford it, my son would love it. He's been asking me for a daft punk helmet. Again GREAT JOB! Thanks for the reply . </p>
<p>r they for sale</p>
<p>Completely finished one is 25k. Yeah, no joke there. It takes a long time to make one, and the parts and electronics used are really expensive.</p><p>Plus, Harrison Krix (aka Volpin Props) is a professional and likes (also deserves) a good hourly wage.</p><p>Don't believe me? Check out his shop:</p><p><a href="http://www.volpinprops.com/product/completely-finished-daft-punk-helmet-replica/" rel="nofollow">http://www.volpinprops.com/product/completely-finished-daft-punk-helmet-replica/</a></p><p>You can get the slush-cast resin base for much, much less but it's still in the triple digits. Or the blueprints for making your own one for a fiver.</p><p><a href="http://www.volpinprops.com/shop/" rel="nofollow">http://www.volpinprops.com/shop/</a></p><p></p>
Oh that's a bit much for me ?
<p>Excellent Instructable Job!!!</p>
<p>Excellent Instructable. You are truly a dedicated and talented craftsman. Thanks.</p>
<p>WOW! Almost too cool to be true ;)</p>
<p>Wow, totally amazing and artistic work.</p>
<p>Harrison! I saw you on tested!</p>
<p>This is really brilliant! favorited!</p>
<p>This is truly incredible! One of the best helmet I ever seen :o</p>
<p>The word Awesome was invented for things like this!</p>
Can you use plexiglass for the visor and still dye it the same way?
<p>That is just ridicuously awesome!</p>
<p>name your price volpin.....</p>
<p>Around $3000</p>
lol dude i could buy like 5000 tickets of his show with that much.<br>I know u r trollin wid me
<p>I guarantee you cant buy a ticket for $1.66 and he's not dude: http://www.ebay.com/itm/Daft-Punk-Full-Led-Gold-Chrome-Helmet-Includes-Gloves-Necklace-And-Stand-/191424388473?pt=LH_DefaultDomain_0&amp;hash=item2c91c85d79</p>
<p>That would be $0.6 per ticket ;)</p>
Would you sell a premade visor pet plastic screen? I don't own a drill press
<p>I don't know if this is what you want but they sell the LED frame here:</p><p>http://www.volpinprops.com/product/thomas-helmet-subvisor-frame-led-holder/</p>
<p>Is it possible to see in it xD</p><p>Just wondering ya know</p>
<p>Hey IF i were to buy the helmet from u how much would u offer it for? 30$???</p><p>email me i anyone wants to sell me one of these? syed.ali165@gmail.com mail me!</p>