I was inspired by the Mr. Hyde character in Nightmare Before Christmas to make an animated top hat. I also loved the cable control creature that Dug North detailed in last year's Make Halloween edition. I wanted a creature that could pop up partially or fully and also move its head and open its mouth.
I have been learning the Arduino board and so thought it would be a great controller.
The Scary Terry web site <http://www.scary-terry.com/> details using digital sound recorders. I also wanted to have sound with my animated hat.
Step 1: Create the Head Sculpture
My first step was to create a sculpture of the head. I already had a costume hat, so I measured the approximate size that seemed likely to hide completely inside the had.
I used Roma non-drying clay and made a quick sculpture. I had some costume jewelry around, so I selected a large and medium fake pearl for eyes.
Once the clay looked good, I brushed on a layer of liquid latex. To give it some body and yet keep it from getting too heavy, I added layers of toilet paper onto the wet latex and then brushed on another layer to seal it in.
Next I added Liquitex paint into the latex and brushed on a thin color layer.
After it dried, I powdered it thoroughly (baby powder or makeup powder) to keep it from sticking to itself and destroying the little mask.