After seeing plans that were not much better than his own sketch (all rolling contraptions), I found a whole slew of Google Images of Dalek dresses. I thought, If I could make a Dalek skirt, he could have a boxy body and Dalek head. With a plunger in one hand, his flashlight in the other would serve as a laser (and grab candy).
He was skeptical, so I focused on the most concrete part--the helmet.
Step 1: Materials
Old bicycle helmet
Old metal bowl (that will fit over bicycle helmet)
2" 5/16 bolt, nut and washers
6" 5/16 bolt, 3 nuts and 2 large washers
3/4" plastic pipe cap--it should be of size so your small flashlight can fit snuggly inside of it.
Horn Lights Idea 1:
2 flashlight bulbs and sockets.
9 volt battery, clip, wires and switch
2 plastic cups
2 metal screws
Horn Lights Idea 2:
2 solar charging pathway lights.
Black rubber tubing
4 metal screws
There is a lot of flexibility in these materials, all depending on what you've got laying around. Those who know something about LEDs and wiring could rig up something much better, I'm sure. In fact, feel free to give (helpful) suggestions and diagrams in the comments section of the electrical step.
Step 2: Helmet to Bowl
Because you will then need to take it off for the wiring, and possibly in the future, I used a bolt to make it easy.
Take the bowl and drill a 5/16 hole in the center.
This bicycle helmet is an old one of my son's, and it has plenty of vent holes--no drilling required. Your helmet may vary.
Putting a washer on the bolt head, pop it inside the helmet and up. Then, place the bowl over the helmet, the end of the bolt sticking through the hole. Tighten the bolt to make sure it sits right, but not too tight because you're going to take it apart in the next step.
Step 3: Dalek Eye
The eye stem is just a six inch 5/16 bolt on which everything rests.
Take the bowl off of the helmet. You'll keep it off until the end.
Drill a 5/16 hole in the bowl where you want the stem to come out of. Then, pop the bolt in, head on the inside. Using a lock nut, crank it until it's tight. Your stem is secure.
You'll use lock nuts to hold the washers in place. Place them so there is enough room on the end to put the 5/16 base.
Glue the plastic pipe cap on to the 5/16 base. Let dry.
Stick the flashlight into the pipe cap. On my flashight, the on/off button is on the base end, so I have to remove it to turn it on and off. If the flashlight is loose in the cap, use some tape and wrap it around the base of the flashlight to increase its girth. When it jams in tight, you're good to go.
Step 4: Electrical
I'm not tech savvy enough to hook up a voice modulator and the like, so my horns just turn "on" and stay on. If you can do it, please make an Instructable and link to it from the comment section here--it would be cool!
Drill two holes in the bowl where the horns go.
I have not gotten the hang of LED lights, which are brighter and won't kill the battery, so I used old flashlight bulbs and sockets. If anyone knows how to wire up some simple LEDs, please post helpful directions in the comments section.
Through the holes mount the light sockets. I used a 9 volt battery as my kid will wear it only an hour (I have no idea how long the bulbs will burn, but I think 9 volts will do). Run the wire. I used a switch and hid it where it is really hard to reach; in hindsight I would just unscrew the bulbs to turn it off.
Finding a cup as a light was tough, but I wound up with a specimen cup. If prescription bottles were clear, they'd be perfect.
Step 5: Horn Light Alternative
Then, I stumbled upon a great solar path light. Perfect shape. Rechargeable (no dead batteries). Cheap.
Because they need to recharge in the sun, the two lights need to come off and go on easily. I went the simple route and used a rubber hose I had and made a stretchy strap.
This is the design I ultimately went with. Much simpler.
Step 6: Wear It
Clean it up (I left price tags on as I built it that needed to be removed) and paint it (if you wish).
White: Supreme Dalek
Yellow: Eternal Dalek
Blue: Strategist Dalek
Red: Drone Dalek
I've seen black and, of course, grey. Why not pink?
Turn on the light (or just let them glow).