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Mr. Hyde Halloween robotic top hat

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Picture of Mr. Hyde Halloween robotic top hat
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.
 
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Step 1: Create the head sculpture

Picture of Create the head sculpture
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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.

Step 2: Create an underskull

Picture of Create an underskull
The little mask has no real structure, so I made an underskull out of aluminum roof flashing (available at hardware stores). It is very lightweight, and you can cut it with heavy scissors. I added a little brace in the back to act as a pivot so that the head could turn.

I also created a jaw and upper palette (the silver metal) so that the mouth could open and close. Black duct tape acts as a hinge between the two pieces.

A very little bit of hot glue attached to mask to the underskull.
dlancaster12 years ago
i want to do this but it looks extremely complicated, this isn't something a novice with electrical components could do?
McNoodle3 years ago
how much did this cost all together?
techiebot (author)  McNoodle3 years ago
As with all projects, that's hard to say. I used a Bare Bones Arduino, which only costs about $10 if you buy a 5 pack. The hat - I've had around for a long time, but it's a cheap felt Halloween costume hat, maybe $12. The Servo I got on eBay sent from Hong Kong - seems like maybe $15 to $20. Clay and liquid latex were left over from various projects. Around Halloween you can find small containers of latex for only a couple of dollars. Plastics, brass, luan base were all just scrap pieces. The voice module seems like it was $30 or so. The best thing is that all of the elements can be taken apart and reused for other fun projects.

I hope that helped.
tenaciousbd3 years ago
Which board did you go with? Is that the one that predates the Duemilanove? Awesome job by the way, I hope my minion turns out with even half the personality of this little fella.
techiebot (author)  tenaciousbd3 years ago
I used a "Bare Bones" Arduino clone. It was of the ATMEL 168 variety and ran the program with no problems.

Good luck on your creation. I'm sure it will have its own personality and be full of charm!
dugnorth3 years ago
I'm so glad you liked my mechanical top hat in MAKE's Halloween special edition and were inspired to take it to the next level! Well done! The scissor lift was a great idea. I wish I thought of that!

All the best,

-Dug North
nak3 years ago
That's insane, love it :)
techiebot (author)  nak3 years ago
Thank you - I live in a rather isolated place, and hearing positive feedback is really great!
nak techiebot3 years ago
No problem, I want to live in an isolated place :P
Your project is just another inspiration for me to get into an arduino
rachel3 years ago
Sweet project!

Also your expression in the first picture is priceless :)
techiebot (author)  rachel3 years ago
THANKS - I really never thought anyone would be looking at it or I would have tried to be more distinguished. Thanks for your comment - I really appreciate it.
jakieboy1113 years ago
how much does the hat weigh and that's pretty cool
techiebot (author)  jakieboy1113 years ago
With the batteries it weighs 1 lb 6 oz. I tried using foam core (one of my favorite materials) for the interior base, but the servo bent it in half. I really worked hard to make it lightweight thinking that my head and neck would be grateful.
bdauterive3 years ago
this is amazing!!! I would love to see this in person if possible.
techiebot (author)  bdauterive3 years ago
I live in a little mountain town in Colorado - so seeing it in person is probably not going to happen.

I hope that the video helped give and idea of how it works.
frogmeetcog3 years ago
Delightfully sick.
Bravo!
raygris3 years ago
excellent well done
jamwaffles3 years ago
Epic! This is so cool lol
too cool man, too cool XD
depotdevoid4 years ago
Hey, that is absolutely awesome!
NEOKOF5 years ago
THE BEST!!!!!
Abhorsen5 years ago
Fantastic!
sir you deserve a presidential commedation this is great and i am going to start immediately
Kiteman5 years ago
That is excellent - shame about the battery life (maybe a belt-full next time?)
techiebot (author)  Kiteman5 years ago
Well, it lasted for the entire school day (8 hours) with intermittent use. I wired the batteries in parallel to provide 9 volts with more power (milliamps). Perhaps I should try wiring them in series? I'll have to check on the maximum volts the Arduino can take. If I mess around some I might get four batteries to fit. Thanks for your comment!
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