Introduction: How to Build Your Own Deadmau5 Mouse Head Helmet!

Picture of How to Build Your Own Deadmau5 Mouse Head Helmet!


So you're a HUGE Deadmau5 fan and have been aching to get your hands on one of those sweet Mau5 heads - but NOT one like some of those epic fail's you've seen some people wear... you want a legit head that will be envied by all.  Well, I'm here to help.  The process is long, it takes a huge amount of determination and patience, but I promise you, in the end, you will have the sikkest Mau5head of any you've ever seen! 

Alright, LET'S GO!!!!


Materials:
14” acrylic lamp post globe with 5.5” neckless opening – any color www.superiorlighting.com
6” acrylic lamp globe – white www.superiorlighting.com
4’x8’ Dow blue extruded polystyrene Styrofoam sheet 1/2” thickness
12” fully threaded rods 8/32” diameter (4pcs)
1 ¼” fender washers (4pcs)
8/32” wing nuts
Professional grade ratcheting hard hat
Lighting for eyes, can use LED’s – I use EL wire from www.coolneon.com
2yds fabric – 4 way stretch is best
Hot glue gun and glue sticks
Liquid Nails for foam adhesive and applicator gun
Stitch witchery
Clothes steamer
Ball end sewing pins
Dremel with bits for cutting, sanding, and drilling
Jigsaw or open ended hacksaw
Fabric measuring tape
Scissors
Single-edge razor blades
Small jaw clamps
Metal Mesh Food Cover Dome
Nylon tights or sheer chiffon for mouth
Electrical or duct tape
Poster board
Sharpie marker
Safety Glasses
Protective Gloves
Wire cutters
Rubbing Alcohol
Black Spray Paint


Getting Started:

Before you begin building your own Mau5head, there is one thing I cannot stress enough, take a great deal of time in the beginning to PLAN. Not only are the collective materials needed an investment, but to create your head properly, it will also take a lot of time – you want your final product to be worthy of all the blood, sweat, and tears that go into its creation! Find a few reference pictures to work from for inspiration and keep those at your work desk, it will help you to visualize along the way, as the head won’t look like much until it all comes together in the end.

For the most accurate replica, a 14” acrylic globe should be used, however if you are very petite a 13” could be used, or if you’re of a larger build you may consider a 16” globe, but in most cases the 14” will be ideal. My measurements are based off of a 14” diameter globe, if you should use a different size, please keep this in mind and adjust your measurements accordingly.


Step 1: Marking Your Globe

Picture of Marking Your Globe

The first step is to mark grid lines on your sphere dividing it into quadrants. DO NOT rely on the little “nipple” opposite the neck opening to determine center, these are often off by a half an inch or more and can throw off your entire layout if used as the midline. Measure 19.25” from the edge of the opening at several places to find the center opposite the neck. Divide your globe into vertical quadrants intersecting at this point. Make a ring of poster board 44” in circumference that will fit perfectly around the globe at its widest point, and use this ring as your guide in drawing the lines. It will help you create a very accurate, crisp line easily. After both lines are drawn completely around the globe, measure from the center point down 11” on all 4 lines to locate the equator midline of your globe. The old phrase, “measure twice, cut once,” applies here as much as it ever could! Before proceeding to the next step, recheck your measurements one last time to make sure they are all equal.

The neck opening should be angled toward the back to both look the best and have the most natural angle when worn. The easiest way to map out the circle for the opening is to create a ring out of your poster board that measures 9” in diameter and place it on the existing opening front. The remainder of the circle will extend slightly up the back of the globe – be sure to check that the ring is equal on either side so that your opening will not be lopsided. Secure with tape, trace around ring with a sharpie, and remove poster board ring.

The mouth opening will rise slightly above the equator line in the center. Mark a dot 5/8” above the equator on the front center line to determine the high point on the mouth. Measure 6 ½” down from this dot to find the lowest point of the bottom lip and mark this point. Now place a dot on the equator line ½” in front of the side line on each side, this will be the outer edges of the mouth. Again, strips of poster board will be incredibly helpful to create even, straight lines. Use tape strips to secure the poster board across the globe starting with the center top point to outer edge points, draw your line with a sharpie. Then, using the same poster board strip, repeat this on the bottom edge from the lower point up to the outer edges. This will create a perfectly curved lower lip, and perfectly straight upper lip.

Don’t worry about marking the ear position yet, we will do that once the ears are built.



Step 2: Cutting Neck & Mouth Openings and Eye Globes

Picture of Cutting Neck & Mouth Openings and Eye Globes

Now let’s move on to cutting the neck and mouth openings. The acrylic globes are thicker near the neck opening, and are tougher to cut, so this is the first thing you need to cut out. ALWAYS WEAR EYE PROTECTION WHEN CUTTING. Acrylic is extremely chippy and sharp when cut, protect your eyes! I use a jigsaw with a medium wood cutting blade on the thickest area near the front of the neck opening, and about ¼ of the way around, switch to a fine wood cutting blade as the acrylic becomes much thinner at this point. Keep a close eye on the acrylic so that you are using a blade right for the thickness you are cutting, too coarse and you risk chipping, too fine and it will do nothing but melt the acrylic. A little trial and error and a lot of patience go a long way here. You can also use an open ended hacksaw for this, or even a Dremel with a cutting blade (but be prepared for a lot of time if you go the Dremel route).

The mouth opening can now be cut, but be very careful not to rest your arm or place unnecessary pressure on the globe. Cutting out these areas weakens the structure, and you want to avoid cracking or otherwise damaging the acrylic during this phase of construction.  ** do NOT cut the mouth out with the jigsaw, the acrylic is very thin here and it will break! **  A Dremel with cutting blade works great for the mouth, and the acrylic is MUCH thinner in this area. Be patient and make 2-3 passes over the entire area to cut through. You can also use an open ended hacksaw to cut the mouth, but again, be careful with the pressure you place on the globe and you’ll do just fine. Keep the cut out piece to use as reference as you form the metal mesh for the mouth later on.

At this point you can get your head inside, go ahead, try it on and make sure the neck hole is large enough and everything is looking even and properly placed so far. Keep in mind that the hard hat will elevate the globe up off your shoulders. You can even slip the hard hat through the neck opening at this point to try on if you would like. After everything looks good, sand any rough edges around the areas that were just cut out.

Since you’re likely covered in all kinds of acrylic bits and dust, this is a great time to cut the smaller white globe that will become the eyes. Mark out 5 1/4"  circles on either side of the white globe and cut out with a Dremel. Smooth edges with a sanding bit or sandpaper on a wood block if you prefer. Remove any remaining sharpie marks with rubbing alcohol and a paper towel.

Step 3: Building the Lip

Picture of Building the Lip

The foam sheet that is used for the ears and lip edge has a thin plastic sheet coating the outer edges. Remove this by gently peeling it off of both sides. Use your razor blade to cut ¾” strips of foam to use to create the lip. Hold your razor blade perfectly straight to cut a flat 90* edge for the lip. Before placing the foam inside the lip, gently bend it bit by bit along the length to create a gentle curve in the foam. Once it holds a nice C shape curve on its own, trim the length so that it is about 3” longer than the mouth opening and slip inside to check fit. Using the low temperature setting on your glue gun, attach the foam to the inside of the globe, making sure to align the foam perfectly to the cut edge of the acrylic and clamp with your small clamps until the hot glue cools and hardens. Work your way around the length of the lip until the entire length is attached. Repeat this process on the remaining lip, trimming the end to fit snugly up against the overlap at the corner of the first lip. Glue the corner area generously, as the junction of these two foam strips helps strengthen the mouth opening. After the glue has cooled, trim any areas that the glue squeezed out of, or sand smooth any areas where the acrylic overlaps too far being careful to keep very straight lines on the lip edge.

Step 4: Creating the Ears

Picture of Creating the Ears

You’ll notice that there are two basic ear shapes used: more round and more oval. I prefer the more oval ears, and my dimensions are based off of that shape, simply adjust the dimensions if you would like more round for your head. Create a template using poster board to ensure all ears pieces are identical. Create 2 cutouts inside to mark where your threaded rods will run through the foam. Using this template, trace 4 ears on the blue foam sheet. **keep this template for future use to create additional sets of ears** Cut outline with a jigsaw with coarse blade or hacksaw. Using the tip of your razor blade, cut two V shaped channels in TWO of the ears deep enough to accommodate the threaded rods. You will be sandwiching two pieces of foam to make one ear, and cutting this channel allows the pieces to fit together flush after the rods have been inserted. Test the channels for fit before moving on.

Also be aware that some fabrics are somewhat sheer, so keep that in mind when marking your foam sheets and assembling ears.  Try to put the printed side on the inside of the ear foam sandwich to avoid any see-through when covering them with fabric later.

Once the channels are cut and fit checked, use low temp hot glue to secure the rods in the channels. The rods only need to extend ¾”-1” past the bottom edge of the ear. Draw a bead of foam safe liquid nails adhesive on the foam and then apply hot glue down the channels with the rods and around the perimeter of the ear. Quickly sandwich the other piece of foam on top and use strips of tape to hold the two pieces firmly together until the glue has set. Repeat process for other ear.

After the glue has set, remove the tape strips that were used to hold the sandwiched pieces together so that the entire edge of the foam is exposed all the way around. Now, take a piece of 300 grit sandpaper wrapped around a wood block to sand the edges of the ears perfectly smooth. You will want a nice flat edge with 90* angle all the way around to have a crisp, finished look to your ears after applying the fabric covering.

Now that your ears have taken shape you can decide where you want them to rest on the head. Again, there are two main positions for the ears: wider set, and higher perked-up ears. The spacing difference between the two is only about ¾”, so be careful when you mark your globe. Hold your ears up to the head to get a feel for where you would like them to sit – don’t place them on the side marker lines, the ear holes should be cut 1” back from the side midlines. Hold them up to determine height placement, mark, and check to make sure they are equally spaced down from the center point at the top of the head.

Now you can cut the holes for the rods to slip through. Your rods will be at an angle, so cut your holes oval to allow for slight adjustment as the rods slide into the head. You don’t want a super tight fit as this could cause the acrylic to crack as they move. Have you ever seen someone split the seat of their pants? Yeah… too tight of a fit.

After you’ve drilled your holes for the rods, attach them to the head with washers and wing nuts. Now it’s really starting to look like you’re getting somewhere!!

Step 5: Eye Placement and Lighting

Picture of Eye Placement and Lighting

With the ears attached, take the white acrylic domes and place them on the front of the head to figure out how you would like them spaced. Use a loop of tape on the inside of the domes to test out different placements and then step back and look at how it looks from the front and the side views on each side as well. Trace the outline of the eye domes onto the head.

Depending on the type of lighting you will be using in the eyes, you may wish to mark out any holes you need to drill or cut to accommodate the lighting source. I use electroluminescent cool neon wire from www.coolneon.com and only need to drill two small holes in each eye area to route the wires. At this point, do not yet install the lighting; this will be done after you have covered the head in fabric.

Step 6: Preparing and Installing Head Restraint

Picture of Preparing and Installing Head Restraint

Next, cut sections out of the hardhat on either side to allow ease of access to the ear attachments once the hardhat is installed. The material hardhats are made of is very glue-resistant, so drill several holes through the hardhat in the area where it contacts the globe and also roughen up the area by sanding. Once you have done a test fit of the head with the hardhat in place, mark out where the contact areas area on the globe and secure the hardhat in place with a large amount of low temp hot glue. Make sure that there is enough glue to ooze through the holes you drilled in the hardhat, creating a mechanical bond between the acrylic and hardhat. Hold firmly in place until glue has completely cooled.

Step 7: Preparing Metal Mesh for Mouth Opening

Picture of Preparing Metal Mesh for Mouth Opening

Previously, in this section of the Instructable, you would have been beating a piece of flat 1/4" grid metal mesh into a curve with a rubber mallet, and probably would have been cursing my name because it is DEFINITELY an exercise in frustration... BUT, I've gone ahead and updated this section to give you a MUCH EASIER alternative that gives you a much, much better looking end result.

The solution: use a large (14" diameter) metal mesh screen food cover dome that is already in the proper spherical curve needed to form the mouth =)  These are best found at your local Asian market, and should cost you around $5

Using the acrylic piece left over from cutting out the mouth, trace the outline of this piece onto the mesh dome and carefully cut the wire, making sure to be on the outside of the  marked line.  Always best to have a little more than you need, than not enough after you cut it out.  Also, wear protective eyewear and heavy duty gloves to protect your hands - the cut edges are extremely sharp!

Once the piece has been cut from the mesh dome, go ahead and do a test fit inside the head, pressing against the foam lip on the inside to see how it lines up with the lip edge. When the fit is good, trim off any excessive overlap of wire (remember you will want at least ½” overhang on the inside to attach to lip). Wrap edges of metal mesh with electrical tape doubled over, or duct tape cut into 1” wide strips and doubled over.  You should not have the tape go very far into the mesh area, just over the very edge to seal in the raw edge of the metal.  This will protect you and your sheer fabric from the sharp edge of the mesh, as well as help you attach the mouth to the inside of the lip.

With the mouth mesh held in place, go into the head from the neck hole and mark dots where you will be placing the screws to hold the mouth in place.  Remove mesh from the head and use a punch, thick nail, or other object to open the wire mesh in the places you will be inserting your screws.  This will make installing the mesh much easier once it is covered with fabric.

Next, spray paint both sides of the mesh black.  This will make the mesh disappear behind the fabric you will use to cover the mouth and because it won't interfere with your eyes from the inside, it will greatly increase your ability to see out of the Mau5head.  A white or silver mesh will be very difficult to see out of and will make you very dizzy - do yourself a favor, spray it black!

Do not attach mouth yet, this will be the last step in creating your Mau5head.



Step 8: Covering Ears With Fabric

Picture of Covering Ears With Fabric

Start by laying your fabric face down on the table and then placing the ear on top of it. Pin around the perimeter of the ear with fabric pins while gently stretching the fabric so it fits nice and tight against the foam. Once you’ve pinned around the entire bottom edge of the ear, trim the fabric approximately an inch and a half out from the edge of the ear, making the fabric easier to handle as you secure with glue. Go around the ear approximately 4” at a time, securing along the top outer edge with hot glue. It doesn’t take a LOT of hot glue, so just make a thin bead of glue, stretch the fabric over, and rub with the other hand to smooth and cool the glue. Continue this around the entire perimeter of the ear. When the glue has cooled, trim off the excess fabric very closely to the foam and repeat process on other ear.

Now you’re ready to do the other side (front) of the ear. The process to pin the fabric will be virtually identical, except now you’ll run a strip of stitch witchery fusible web around the top edge of the ear. Pin the stitch witchery in a few places to hold until the fabric is stretched over it. Now, very carefully go around the perimeter of your ear stretching the fabric up the edge and over the back, and pin the fabric at the back of the ear. You are doing this to give a tight fit up against the stitch witchery, but not pin exactly to it. After you’ve gone around the entire ear and gotten a nice smooth fit all the way around, steam around the edge of the ear with your steamer to melt the stitch witchery and adhere your fabric edges together. Move slowly around the edge, allowing 10 seconds or so over each area to fully adhere the fusible web. Let the fabric cool completely, and then trim the edges. This will be your finished edge, so give a little teeny bit of stretch to the fabric as you trim it to get the smoothest even cut along the edge.

Secure the edges bottom near the rod ends with hot glue, making sure they are very smooth – this edge rests against your head and an even surface is very important!


Step 9: Covering the Head With Fabric

Picture of Covering the Head With Fabric

In this step, be extremely patient! You’ve put so much time into your Mau5head that you want the “icing” on this cake to be perfect!!! Some fabrics are somewhat see-through, so before you put the fabric on, remove all sharpie markings with rubbing alcohol.

Play with your fabric a bit to get a feel for how/where it stretches. Place it on the globe in several areas and stretch it to get an idea how it will mold to the area you are about to cover. I like to start with the bottom lip/back first. Use your C-clamps to hold the fabric in place after folding over the bottom lip, and stretch the fabric up and around, securing with clips or pins as you go. If you have a friend who sews, bribe them with free pizza and ask for help. A seamstress’ experience can be invaluable if you have one you can borrow for the afternoon.

If you need to, you can tack the fabric in place with a *tiny* dot of hot glue. Remember that the glue can seep through many fabrics, so test on an inconspicuous area first. After the fabric has been stretched into place, you can secure with hot glue, or with stitch witchery if you will be overlapping fabric to fabric (stitch witchery between fabric layers and steamed to adhere).

On the inside of the lips, use hot glue on the back side of the foam – not on the lip itself! You want the fabric taut over the foam lip edge and secured only on the back where the metal mesh will touch.

Repeat this process on the top half of the head, and at your seam you can either trim smooth or roll under for a finished seam like a sewn edge would look. Secure with hot glue or, my preference, steam edges together with stitch witchery.

Secure fabric on inside of neck with hot glue after rolling fabric over cut edge of neck opening.

Cut small slits with a razor blade through holes for ear rods and any holes cut for eye lighting.

Step 10: Installing Eyes

Picture of Installing Eyes

Now that your head is completely covered with fabric, reattach ears. This will help make sure the eyes get positioned properly. Go ahead and put in whatever lighting source you have chosen. If possible, try to put a reflective material such as foil as a background in the entire eye area to intensify the light output from the eyes. Secure the power source to the inside of the head with self adhesive Velcro strips.

Test fit your eye domes over the lighting and inspect for placement. When you are satisfied with placement, run a thin bead of hot glue around inner edge of the white acrylic dome, one at a time, and place over lighting source. Be careful to not drip any glue on the fabric of the head.

Step 11: Installing Mouth

Picture of Installing Mouth

Finally, the last piece of the puzzle is ready to go in! Cover the metal mesh mouthpiece with either a piece of nylon tights material, or sheer chiffon fabric and secure edges with either hot glue or tape. Place the mesh inside the head, holding edges tight against inner edge of lips. You will be securing the metal mesh in place with screws so that you can replace fabric if needed, or make other adjustments without having to battle a hot glue mess later down the road. When you have decided where you would like the screws to attach, pierce through the tape edge of the mesh to cut through the tape and fabric, and to start a path for the screw to go through into the foam lip edge. Screw through this slit into the foam, and repeat in several places around the mouth edge. Check from the front from time to time, and see where the mouth needs to be screwed in, giving the proper shape to the mesh.

Step 12: YOU DID IT!!!!!!

Picture of YOU DID IT!!!!!!


The last step is to ROCK THAT MAU5HEAD!!!

Switch on the lights and put on that amazing Mau5head you just created, and rock it like you mean it! You deserve it ;D


Comments

sigpop (author)2012-10-19
I used your very well-done directions to make a deadmau5 head for my boy for Halloween this year.  Here are a few tips/tricks (wall of text warning):


Use a new very sharp blade to cut the foam for the ears and lips.  My cuts weren't the cleanest as I was out of blades at the time and used the old one I had in my utility knife.  Too much crumbly edges.  I was able to sand down the edges to clean a lot of it up, and the fabric does hide most imperfections.


When cutting the acrylic globes, I used my dremmel.  Go back with a utility knife to clean up any flashing (jagged edges of plastic that remains along the cut edge).  Don't use the dremmel sanding bits.  I did on my eyes and it chewed a few of the edges more than I would have liked.  Hand sanding the edges worked fine.  I ended up lining the edges of my eyes with a black rubber trim that I used to line some metal edges when I hacked a hole in my computer case.  It actually looks nicer than just having the plastic eye glued onto the head, imo.  It looks like this stuff:
http://www.frozencpu.com/products/5096


As frustrating as it was to get the seams done cleanly, in hindsight I might have checked about painting the thing.  My material was very stretchy.  I think it was 19% lycra and came from the "dance fabric" section at the fabric store.  My kids said it felt like bathing suit material.  I think it was too stretchy, in fact.  It was hard to cut a straight line.  When you give the fabric a slight pull to cut the seam close, it will never result in a straight line cut over a few inches.  This may also be a result of my expectations of a seamstress-quality job, though.  From a few feet away you can't really tell, and it's fine for my purposes.


I used double sided tape to hold down my fabric along the back of the globe.  I started by clamping the fabric on the bottom lip and working it back to a piece of double sided tape along the back, then trimmed the bottom piece along the tape edge.  Then I put another piece of tape adjacent to the first and used that for the top piece of fabric.  You can pick the fabric up off of the tape and work/stretch it to remove wrinkles.  To finish it, I laid a piece of the stitch witchery stuff on the bottom piece and pulled the top piece over top and fused them together.  Then I went back and trimmed the top as best as possible.  Trimming the bottom piece precisely wasn't as crucial since the top piece covered it.  I spent a little more time trying to make a clean cut on the top.


Speaking of clamps, these paper clamps worked well and were cheap:
http://www.thezigzagger.com/2011/12/29/cable-holder/black-paper-clamp/


I had to use very small dabs of glue to hold the stich witchery in place.  It slipped off when I was doing my first ear and made a bit of a mess of the first seam. 


Keeping the hardhat glued to the inside of the globe was a big pita.  After roughing up the surface and drilling holes in the hat, I dumped a bunch of hot glue on the top and held it in place, but it was still weak.  I cut four simple braces from the foam used for the ears and lips and braced the hat to the sides of the globe.  Worked great to steady it up.


I let my kid pick the colors and lights;  he chose red.  Unfort, red EL wire is not really red.  It's more of an orange.  I personally liked the "blue-green" color because the wire itself is clear until it's turned on.  I used really cheap EL wire from Amazon.  Thatscoolwire.com or coolneon.com have nicer and brighter stuff.  Some EL tape would have been neat to trim the ears, too.


I used some cheap Fusion Reactor necklaces for the eyes.  This company sells them and other blinky party junk on the cheap.
http://www.windycitynovelties.com/gcssearch.aspx?w=fusion


I pulled them apart and soldered this battery holder to them.
2 x CR2032 6v battery holder with switch
http://www.adafruit.com/products/783


I wanted to move the EL power sources out of the head.  Less weight on my kid's melon, plus it moves the high-pitch driver for the EL wire away from his ears.  He'll just snake the wires down to his pocket. 


I originally drilled the holes for the eye lights too small for the connectors that I soldered onto the reactor necklace.  I used the side of my soldering iron to make the holes bigger (and squared them off since that was the shape of the connector).  Probably not healthy for your iron, but I didn't want to mess up the fabric after working so hard on it.


For the mouth I used a roll of metal mesh like this:
http://www.lowes.com/pd_90-16418-122410_4294753353__?productId=3160773&Ns=p_product_price|0
Somebody suggested this red mesh food cover from Camping World.
http://www.campingworld.com/shopping/product/mesh-food-covers/6536
I tried it and it wasn't big enough.  The metal mesh I used was pretty easy to work with since it came in a roll.  It wasn't hard to shape it for the mouth.


I also added some teeth.  Using the piece of the globe I cut out for the mouth made it easy because it was already shaped.  I sprayed it with some silver adhesive glitter spray to give it a little shine.

http://youtu.be/05fwlbaN5HM
jmanschlief (author)sigpop2016-02-16

I used the dremmel to go back around the mouth and make small adjustments making sure to be careful. As far as the eyes go, I layed a piece of 320 grit sandpaper on the ground and sanded away the rough edges.

Intrica (author)sigpop2012-10-26

Great comment man, thank you! I really appreciate and respect the collaboration of everyone on this instructable's comment thread. YOU GUYS ROCK!

skeester45 (author)sigpop2012-10-23

Really great work and thanks for the explanation on the fabric. I have read all of the comments a ton of times, and I am at the final stage of getting the fabric on the head. I have spent hours trying different techniques but have taken the plunge of cutting of debulking the fabric. So it seems you have a seam at the bottom-back of the head? I am considering using your technique, so any more suggestions would be greatly appreciated

sigpop (author)skeester452012-10-23

My suggestion:

1. Lay one piece of tape horizontally across the entire back of the globe and stretch either the top or bottom piece of fabric to it. I used clamps and/or pins to keep the opposite end anchored to the lip in the mouth.
2. Smooth it out and glue it permanently behind the lip in the mouth.
3. Trim the fabric tight to the tape. No need to leave any overhanging. No need to be overly neat here because we will cover the seam (see step 6 below)
4. Then lay another piece of tape directly adjacent to the first and do the other half.
5. Trim this piece tight to the tape, too. Cutting stretchy fabric with scissors sucks--I didn't have a clean seam, so...
6. I made a "cover up" piece. My wife informed me that proper fabric cutting is done with a circular blade like this:
http://tlc.howstuffworks.com/home/cutting-fabric-for-quilting.htm
I cut a piece approx 3/4 of an inch and put some stitch witchery behind it and fused it over top of my seam to hide the uneven cuts.

In my pics below, the first one is the ugly seam I orig made.

The second pic show what my cover-up piece did to hide it.

Mine is even more bumpy because of my first attempt to make the seam without the cover-up. If I would have planned on using the cover-up in the first place it would have been smoother. The flash on my camera coupled with the sheen of the material seems to over-emphasize the bumps, too.

In hindsight this approach would have worked well for the ears, too.

skeester45 (author)sigpop2012-10-23

sigpop - fantastic description and pics. This is exactly what I was looking for and am sure it will help many others as well. My wife has one of those cutting wheels, so I will definitely use it to cut the 'cover up'. One more quick question - does the cover up piece go all the way around to the corners of the mouth? Thanks again for the great info.

sigpop (author)skeester452012-10-23

Yeah, mine goes all the way around. Looks kind of like an extension of the top lip if you view the head from the side. It would be nice to have no seams, but that seemed impossible. Thankfully you can't see the seam from the front.

skeester45 (author)sigpop2012-10-23

I hear ya on the impossible - just dont see it. I cant even begin to see the seam on the front of the head in your pics, so thats great. heck thats the whole reason I asked since they dissapeared in the pic. Looking forward to going with this method tonight and finally finishing up. Thanks again for all of the great tips

Funky JL (author)2012-10-26

Thanks for the instructions Intrica! A lot of trial and error. This was my first Deadmau5 helmet. Deadmau5 with a touch of Iron man.

AshwinN3 (author)Funky JL2016-01-27

Hi, that's an awesome mau5head! Can you tell me how you got that smooth metallic finish? Is it possible on a globe made of paper mache? thanks!

jmanschlief (author)AshwinN32016-02-16

You would need to apply some material to make a smooth finish. That is why polycarbonate or acrylic globes are so popular with this because they already have such a smooth surface and are easy to dremel. I smoothed alot of my project out with the mouth and the ears using silicon, but other products such as fiberglass resin is a popular product. With fiberglass resin, be sure to use gloves and to be outside(I had a terrible experience with that haha).

Funky JL (author)AshwinN32016-01-27

I bought the spray paint cans at Home Depot. Unfortunately, it won't have that smooth finish on paper mache. I bought a plastic globe through Amazon. It looks much better on it. I was suppose to do a Megaman one but never had the time to finish it. Hope that helps.

Intrica (author)Funky JL2012-10-26

Love it!!!!!!

wissahickey (author)2012-11-01

Thanks for the directions!

I think it came out pretty well. I hand stitched the globe material and used simple battery operated xmas lights for the mouth and glow sticks stuck in the eyes...simple but effective!

My 10 year old (and his brother) love Deadmau5, and he felt like the real thing...what more cold a mom ask for?

;)

DJ SLIMBEATZ (author)wissahickey2015-06-23

thats sweet. i love it. my favorite pic is the middle, it has that mysterious glow

Intrica (author)wissahickey2013-04-14

how cute!!!

mpaulk (author)2012-10-29

Thank you so much for the instructions, they were fantastic!!! Along with Deadmau5's released specs on the Mau5 head (http://www.jadorehousemusic.com/make-your-own-deadmau5-head-8d/), it all came together really well. Unfortunately, I jumped the gun and cut out the neck hole before measuring anything...so it made it about a billenty times more difficult to get things accurate and straight. The ears ended up a smidge off and the upper lip not quite as high as I liked, but, meh, you live you learn. The next one will be even better! I didn't want to tackle adding cloth to mine so I recycled old materials for the covering on the head and ears (CD's I previously ripped to digital and cut apart with tin snips) and hot glue gunned each piece on after spray painting the head glossy black ;) I added fusion reactor lights in each eye and EL wire around the ears.

Intrica (author)mpaulk2013-04-14

I LOVE the creativity!!!!! Great job! Thank you so much for sharing =)

AceTehWolf (author)2012-11-02

Just made mine in time for Halloween. Brought it to school and everyone loved it :) Thank you so much!

Intrica (author)AceTehWolf2013-04-14

Awesome! Thank you for sharing!!

AceTehWolf (author)AceTehWolf2012-11-02

I guess it helps if I post it haha the eyes glow up too.

instruktme90 (author)2012-11-22

Here it is! Made it just in time for this year's halloween!
Thanks for the instructions! wouldn't have been able to do it otherwise :D

Intrica (author)instruktme902013-04-14

Yay!!! You're very welcome, happy to help!! Looks wicked!!

Image uploader wasn't playing ball.

here we go!

&

HeroStep (author)2012-11-26

Great instructable, really easy to follow and allowed for me to add my own customization without losing faith in the integrity of the Mau5head. I plan to make two more heads this winter (Monster Energy inspired and a ironMau5 (iron man)

Red EL Wire
White LED and RED/BLUE flashing eyes
Red Equalizer

Intrica (author)HeroStep2013-04-14

Awesome!!!! Can't wait to see the next installment! Thanks for sharing with us!!!

kdelane (author)2012-09-25

Great tutorial! Really helped me with my Mau5. Love from JA.

Intrica (author)kdelane2012-10-26

AWESOMENESS!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!

kdelane (author)kdelane2012-10-02

boom

kwhite24 (author)2012-10-24

We didnt have a lot of time before our cub scout party, but we combined our love of Deadmau5 and Star Wars to create our own Droids n Stuff

Intrica (author)kwhite242012-10-26

omigosh how fun are these!?!?!!

canides-valles (author)2012-09-16

Followed the instructions and added an internal aluminum frame, glowing eyes that show X's when on are blank when off, and ventilation fans

Intrica (author)canides-valles2012-09-23

great work!!!! love the incognito X's on the eyes!

XEblaw (author)2012-07-11

Finished mine a while ago, but forgot to post here. Thanks for the awesome tutorial!

Intrica (author)XEblaw2012-07-11

VERY unique! Great job! Hope you can breathe in there =)))

XEblaw (author)Intrica2012-07-11

Thanks, I can breathe fine in it, actually. I do have a little trouble seeing out of it sometimes, but I can see just enough.

Loljim (author)2012-04-16

Finished my 2nd one. Never again will I touch a rhinestone. Thanks again for this amazing guide!

Intrica (author)Loljim2012-07-11

Looks GREAT!! Awesome job! =D

TopdeK (author)2012-06-10

Hi Intrica,

Just wanted to say thanks for the instructions. I found the dimensions, tips and advice on certain parts very useful in the construction of mine! Its built from fiberglass, bodyfiller and the mouth is even made from perforated aluminium metal sheeting. I think it turned out class! Couple of imperfections on it but they could have been fixed had the time frame not been cut so short. I wanted it for the gig last week so ran out of "casual" time.

Nonetheless, check it out!!

Intrica (author)TopdeK2012-06-10

TOTALLY KILLER!!! Amazing job! Gotta ask, though, how much does that bad boy weigh? :yikes:

Excellent work my friend, please, please, please send printed pics to Joel at his fanmail address. HE. WILL. FLIP. !!! =D

Thank you so much for posting pics, and sharing your work with us, phenom job man! woot!

TheViper (author)2012-05-06

I just spent about half an hour creating this template for the ears because I am, unfortunately, a perfectionist. It is all done with the ruler on Microsoft Office Word 2010 and cannot be viewed correctly on a lower version (I tried, sorry!). All you need to do is print on four 8.5"x11" size pieces of paper, line up the cross on each paper, tape, and cut out everything except the red section, including the purple part at the "bottom". It is the official dimensions of the Mau5head. Have fun making this! Great instructions, by the way.

NOTE: This template only works for 14" diameter Mau5heads.

TheViper (author)TheViper2012-05-06

For those of you without Microsoft Office Word 2010. I am unsure if the dimensions translated correctly into the .pdf file, but they should have. Please let me know if there is a problem.

TheViper (author)TheViper2012-05-06

Revoker (author)TheViper2012-05-15

there seems to be a problem that i had with this the final measurement came out to be about 12.6" instead of the 13" im going to use the 12.6 out of laziness but i just wanted to point this out

TheViper (author)TheViper2012-05-06

To be honest, I skipped the "two-halves make a whole" method and went directly to a 1" thickness ear. I cut the Styrofoam using an Exact-O-Knife (after tracing the template onto it) and then used a drill press to create two identical, parallel holes in the material. I suppose the only problem with this is that everybody doesn't have a drill press, but if you do or have access to one, I definitely suggest this method.

PatentPending (author)2012-01-19

Thank You! :D

It's such a treasure to me, I love how I made the back logo a special light, you can't tell it's there when it's off!

Intrica (author)PatentPending2012-02-28

LOVE IT!!!!!

hlsiao (author)2011-12-29

This is amazing!!! Thanks so much. I made a Christmas hat with the deadmau5 Christmas ornament at the end, and I think it worked out really well.

Have you tried to do anything with other materials, and accessories? I love the top hat in your other photo, and some of your other designs.

I'm currently trying to experiment with making a fiberglass head, and also painting them. Have you gone into this area at all, and have any advice?

Intrica (author)hlsiao2012-01-13

You're welcome! Thank you so much for posting pics!

I love to do silly stuff with my mau5heads, whether it be adding accessories, changing out different ear colors on the same head base, or going totally crazy with the styling (as shown in the pink mau5head I made for his gf Lindsey!) Be creative, add your own flavor to it, have fun with it!

I personally would not make the head out of fiberglass, as it would require too much resin and fiber to be strong enough, and although it sounds easy to get a perfect sphere, i can assure you it is not. You can paint the acrylic if you wanted to, no reason not - many people have done that with great success.

Keep us posted on future ideas!