Hi Guys

I am going to attempt to show you how I made my Daft Punk Helmet and suit from the film Tron.

We go to a festival each year that is mainly fancy dress and this year we had an epic task of making these suits. My helmet was fashioned from a Boba Fett Helmet from start wars and 8 months and about £250 quids worth of modelling gear.

The main materials used for this were:
  • Black sticky back vinyl
  • 2 x light strips for eyes
  • 4mm plasti card for face sculpting and ear pieces and head band across the top
  • Asetate sheet for eye visor
  • blue cable for rear of head
  • lots of araldite
  • Silcion, silver
  • sand paper for sanding edges down, wet n dry
  • sticky back mirror sheet - vinyl
  • Modelling foam for ear pieces (first attempt)
  • LED's for ear pieces, single hi power blue 3V
  • Filler spray (melted the foam, spray lightly and build up)
  • Black and Silver spray paint
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Step 1: The original Helmet

Picture of The original Helmet
The helmet was made from a Boba Fett helmet which i cut to pieces and added some things to change its appearance.

I cut away a lot of the front and replaced it with plasticard and aluminium sheet.

Step 2: Installing Eye LED strips and Chrome on top of helmet

Picture of Installing Eye LED strips and Chrome on top of helmet
i started by adding the lights to the main eye section as we needed to make sure things fit properly.

I then started to add some chrome sheeting to the top of the helmet to change its colour and texture. I tried to put it straight on to the helmet and it didn't work too well, i had to cut them into triangles and lay them over one another to make them fit better and not overlap so much.

As you can see from creases in this photo, i didn't get it right first time...

Step 3: Cutting off Boba Fetts face...

Picture of Cutting off Boba Fetts face...
i started to cut away any material that wasn't needed and that was also going to get in the way of any future modifications.

The face piece was then replaced with once sheet of 2mm plasticard and then the aluminium on top of that.

Step 4: Faulty products!!!

Picture of Faulty products!!!
Once the eye piece was fixed into place it became apparent that one of the lights was faulty, so i took it apart again and sent it back to the guy from ebay that sold it me... once done it worked fine.

Step 5: Wires on the back of head

Picture of Wires on the back of head
The wires were just cut to length and threaded into place to make this affect.

I stuck them down with a little clear silicon, which i put under the plastic at each end of the wire and i also smeared some across the helmet under the wires.

The white strip across the top and around the sides is raised slightly with plastic spacers to enable me to get the wires underneath the edges. All the spaces are held with areledite.

Step 6: Robot Ears

Picture of Robot Ears
The ear pieces were made with a long strip of plastic bent and fixed in place to create the top curve and a piece cut and fitted to the front, i used the modelling foam to make templates and then fitted the plastic around them. 

Once the plastic ear pieces were put together i covered them with the chrome sheeting and siliconed them to the head, the were a pretty good fit, but i had a little trouble getting them on straight.

The waveform  on the black disc was made from 2mm plasticard. I masked the shape on and then sprayed it black and then lacquered it.

Step 7: Face piece

Picture of Face piece
Once the aluminium chin piece was fitted i started to apply the black face film and had to apply layers that overlapped slightly to get the smoothest effect possible.

Step 8:

Picture of
For the visor that covers the lights in the eyes i used very thin acetate sheet and then tinted it with tinting film.

I worked very well and hid a lot of mess around the eye cut out. it also dimmed the lights down just enough as they were super bright without it.

Step 9: Tidying up

Picture of Tidying up
Once the majority of the work was done, i sprayed the inside of the helmet black to neaten stuff up.

Step 10:

Picture of
For the gloves i sketched out the shapes of the plates on the back of the glove.

I covered some plasticard in chrome sheet and then cut the pieces out.

They are attached to the glove using areledite, i tried silicon but them just peeled of as they were too smoother surface.

Step 11:

Picture of
I went around the helmet and filled any gaps with silver silicon and then smoothed them all out, this really made the helmet strong and looked smooth.

The lights were run using a 12v 8x AA battery holder with a jack plug connector going to the helmet and the suit. The Discs on the back of the suit also ran from the same power supply. 

The Helmets were wired with a separate on/off switch to enable us to leave the suits on and reduce glare from the inside of the visor. it was pretty hard to see walking around a festival at night with the helmet lights on.
carlpogi_113 years ago
domtrofski (author)  carlpogi_113 years ago
cheers pal...

happy new year
nerd123 years ago
how can you see with blinding LEDs in front of your eyes and between you and the visor surface?
domtrofski (author)  nerd123 years ago
The back of the lights are heavily masked with duct tape to block out any light, however the glare from the visor is quite bad at night, daytime is fine.

scarr563 years ago
Who was the eBay vendor who made the eye (lights) piece?
domtrofski (author)  scarr563 years ago

Search for 'LED light strips 12v'

There is two strips, each folded once to make four layers. It's like a rubber strip that some people stick to their cars lights...

Hope that helps

LucDaRocka13 years ago
hey man, u know that in alot of songs where they make a robot voice? its a talkbox, like they use for guitar except for a keyboard..... u should get a talkbox, hook it inside the helmet, and have a keyboard with a strap on..... it would give a goood effect....
domtrofski (author)  LucDaRocka13 years ago
I will defo look into mate, thanks for the advice!

Keep it daft.........punk

Reminds me of mr. video from bit trip

Doctoroke10 months ago
I would really like to make this before Halloween but I can't find the boba fett helmet you used. Where did you get yours and how much did it cost?
Mr_Gone1 year ago
How did you make the visor?
Heat gun? Over and form casting of sorts?
ibrown61 year ago
Can make a video of this
epicface1232 years ago
You could sell these for a living... :p
o__o2 years ago
What did you use for the visor?
sd2kool4u3 years ago
where did you get the plasti card?
sd2kool4u3 years ago
i chromed the helmet and removed all the screws i could find but just can't get it apart did you use a dremel to get the the face apart?
LucDaRocka13 years ago
yeah the cheapest one is this one in america: getting one used can save some money, just change the tube.......
rekaks3 years ago
what? you destroyed the fett? :(
domtrofski (author)  rekaks3 years ago
Its fetts fault for having such a lovely 'daft punk' shaped head.

oh poor fett, nice job though!
rkeyzer3 years ago
Why why must you do this to the fett man
domtrofski (author)  rkeyzer3 years ago
Needs must dude, needs must...