I like to stay away from trendy Halloween costumes. What's worse than showing up to a party dressed the same as someone else? I also like to make or build as much of the costume as possible. If you are reading this Instructable, you probably agree that's the best part!
This year I decided to become a deep-sea diver.
Materials in the helmet:
- 12" cardboard Earth globe
- 3pcs 4" rubber taillight grommets (found at Princess Auto)
- 2 stove trim rings (small)
- medium-duty hinge
- pill bottles, random knobs
- spray paint (copper and leather colors)
- optional: iPod, 9V battery, white & blue LEDs, on/off switch
Materials in the rest:
- white painters suit
- white gloves
- carpeting knee-pads
- black boots
- 2 leather belts
- 2" wide elastic
- styrofoam sheet (large enough for chest piece plus some extra)
- Great Stuff expanding foam (1 can was enough)
- carpet tacks
- duct tape!
Step 1: The Helmet (building)
The 12" globe was one of the few parts I knew I would need. The rest was mostly scrounged from my scrap bins or found by chance wandering through surplus stores.
Once I had the taillight grommets and stove trim ring taped in place where I wanted them, I traced with a marker so I would know where to cut. I happen to have a set of large hole saws and one fit the grommets pretty good. The face and neck holes had to be enlarged with a jigsaw.
The grommets and inner ring were then Gorilla Glued in place. I highly recommend this glue. It bubbles and expands to fill gaps, but dries super hard. I sprayed some Great Stuff expanding foam (a new favorite building tool) to smooth the gap in the trim ring. A sharp knife cuts the cured foam like butter. It was a dream to work with.
I found a good looking gate hinge at the hardware store. I cut it to fit the trim rings then drilled holes and mounted to the inner ring with rivets, and the outer ring with screws and nuts.
I also added a cardboard collar that would slide into the hole I would make in the chest piece.