Picture of Light up and Talking PotatOS from Portal 2
This Instructable is for a light up and talking PotatOS from Portal 2. She was made as a college project which had a size restriction of 1ft cubed. She was also used as a means for me to get to grips with electronics which I'd never incorporated into a project before plus I really wanted my own talking Potato! 

[EDIT: Oh wow! A lovely featured sash across my Instructable, that's so awesome!] 


Materials Required: 

NOTE: none of these materials are set in stone, if you can find a better material to incorporate into the project let me know! I'm always keen to know an easier way to do things!

Insulation Foam,
Foam Glue,
Car Body Filler (I used Ispon, the American version is Bondo by 3M),
Red Filler Putty (this is optional but gives a smooth finish, also by 3M),
Two Part Epoxy Putty (I used Milliput but there are many brands out there), 
Grey Primer (Optional),
Smooth-On Rebound 25, Oomoo 30 and Smooth Cast 305
Hard Plaster (Or alternatively Smooth On Plasti Paste or Fibre Glass)
One Step release agent (or any silicone release agent)
Thin Modeling Wire,
Thick Modeling Wire,
Black Wire Covering (I took the black covering off an old monitor cable which fit over the modeling wire perfectly),
2 Nails,
2 Crocodile Clips,
Acyrlic Inks,
Warhammer Tin Bitz and Boltgun Metal Modeling Paints (Optional),
Tamiya Weathering Kit (Optional), 
White Spray Paint,
Red Enamel or Acrylic,
Styrene and styrene tubing of various sizes (Cheaper option for styrene tubing: Ask an art shop to keep all the tubes from the top of brushes next time they get a delivery in!),
Yellow Electrical Wire / Rubber Bands (The straps around PotatOS are meant to be rubber bands, I used yellow wire by mistake, seems so obvious now!)
Super Glue,
3 Yellow LEDs
Some Electric Wire and Tape
A few Female Jumper Cables (Probably only needed if you use the same sound module I did, each module is different)
1 6v Battery and Holder
1 9v Battery and Holder or Connector
1 Sound Recording Module / Chip
1 Speaker
1 on/off rocker switch
2 Mini Push Buttons
2 Large Push Buttons (If you're making a stand like I did)
Hook and Loop Pads
A fair bit of sandpaper (I used grades ranging from 60 to 1200)


NOTE: Again, you don't have just the one option for each method! 

Rotary Tool,
Sanding Blocks,
Steel Ruler,
Spatula (Lollipop sticks make good disposable spatulas),
Breathing Mask and Eye Protection (I was very bold and didn't always use my mask but trust me car filler damages your health something fierce so take lots of precautions!),
Nitrile Gloves,
Sculpting Tools,
Disposable Cups for Mixing, 
Router Tool / Lathe 
Soldering Iron
Needle Files (Optional)
Airbrush (Optional)
Paint Brushes
Calipers (Digital is best but not essential!)

Computer Programs Used

NOTE: These probably aren't all essential, but helped a lot.

Portal 2
3D Ripper DX
3ds Max Student Version (Autodesk are amazing, if you're a student, they give you their software for free!!)
Any Graphic Software (eg: GIMP, Inkscape, Photoshop, Illustrator etc)
Any Good Music Player (eg: Windows Media Player, VLC, etc)
Nem's Tools: Crafty and GCFScape

great job buddy...keep up the good works...n thanx for share...
nerd972 years ago
Alright, yes, this is awesome, but if your lazy you can buy pretty much this exact thing in a kit from thinkgeek.com . I might upload a pic of it if you want to see it...
codename-3c (author)  nerd972 years ago
Cheers for the comment =) I already know about the Think Geek kit, I think it was like two or three days after I submitted this project in college that it was released! lol, I was lucky because if my lecturer's had seen it they'd have said "but it already exists...."
Personally I think the Think Geek one looks a bit too clean... or newish, also you have to find your own potato, lol, whereas mine is dirtied up to look like the one from in the game. But you're totally right, to save time you could get the one from Think Geek and just make the potato, as a real potato will eventually grow and take over your lab and no one likes cleaning up acres of broken glass...
Now make a portal gun and mount GLaDOS on
or PotatOS
codename-3c (author)  desmondtheredx2 years ago
Aye, tis on on to build list! =D
how about whealty?
codename-3c (author)  c3ralki1l3r2 years ago
Oh yes! Or Space core, I've seen someone who made a hand operated Wheatley puppet a while back, I'd love to make an automated one to hang from the redunent TV bracket in my room! =D
This is the best Portal 2 instructables I have reversed seen! !! You are awesome I worship you, could you please check out my instructables? Again, I worship you
So sorry I never got a message about this comment! Thank you so much for your compliments! I'm off to check your stuff out now =D
OMG! You my friend are a golden god of making. I bow down to your skills!
codename-3c (author)  JoshuaZimmerman2 years ago
Wow what a compliment! Thank you ^_^
You seriously deserve it. Great electronics skills and craftsmanship. It looks like a real prop that could be used on screen. (And I am seriously envious and want one of my own! If you sold them I would buy one from you.)
codename-3c (author)  JoshuaZimmerman2 years ago
Making me blush! I've been toying with the idea of selling raw casts of the potato and eye if people want them. If I decide to do so I shall let you know =D and thanks again for the compliments!
zorwick2 years ago
Very well done! Thanks for sharing it! Love your work and Portal :)

"Oh. It's you. It's been a long time. How have you been? I've been really busy being dead. You know... after you murdered me. Look. We've both said a lot of things we're going to regret. But I think we can put our differences behind us. For science. You monster."

codename-3c (author)  zorwick2 years ago
Thank you =)
toezar003 years ago
codename-3c (author)  toezar002 years ago
Thank you =)
darkbain2 years ago
This gets a huge WOW. I love Portal, this is way sweet. Plus I'll be checking out 3D Ripper DX now :).
Great work.
codename-3c (author)  darkbain2 years ago
Cheers =D
DoctorWoo3 years ago
This is fantastic! I've been trying to figure out a way to make a fake potato for a portal cosplay for a bit, and this nailed it! Thanks for the share!
codename-3c (author)  DoctorWoo3 years ago
Awesome! Don't forget to pop back to post a picture, I'd love to see how it turns out =D