How to build robot halloween costumes.

Step 4 Building The Eyes & Heads

For the eyes, the LED puck lights were an almost perfect fit. I wrapped a small strip of duct tape around the perimeter of the light and it made a snug fit inside the lens housing. The lights by them selves would make great eyes for a costume but I was committed to using the lenses.

The eyes were then secured into the face piece with duct tape as shown below. Then I riveted the assembly together using the formed angles and sheet metal pieces I made at my work. This turned out to be harder than I thought as my design didn't leave much room for error on any level. I should have planned for more fudge room where the aluminum sheet would be coming together in the corners. It all worked out in the end though.

Next step was installing the aluminum louver vents for ear pieces. This was also accomplished with duct tape.

Then I ripped the shells of two old bike helmets and used a hand saw to cut them down for each head. My girlfriend then used duct tape and old upholstery foam to secure the helmets in place. The duct tape didn't like to stick to either the helmets or the foam and the helmets worked their way loose over the course of our party. We will need to find a better solution for securing them. Possibly another kind of tape or some epoxy or something.