The project was a success, my group could easily find each other and we had fun bobbing around with it during the late night sets.
We received a lot of praise and many people have been asking us how we made it. I figured this would be the best spot to post it.
Hopefully you can be inspired to create something similar!
• Box Cutter / Xacto Knife
• Paint Brushes
• Black Duct Tape
• Foil Duct Tape
• Blue Painters Tape
• Black Acrylic Paint (for solids)
• Yellow & Blue Enamel Paint (for transparent)
• 2x - 24"x36" sheets of Transluscent Cor-plast
• One equal sized sheet of paper for stenciling
• 4x - 3" long bolts
• 16x - washers
• 12x - nuts
• 2x - 3' Paracord 550
• Telescoping Flag Pole (20')
• Hula skirt
• Battery powered string of micro-LEDs (http://amzn.to/14CxcyT)
• Small Carabiner
• A friend or two
Step 1: CUTTING THE COR-PLAST:
Cut those pieces out and use them for tracing out the exact same shapes on the other sheet of Cor-Plast. Then, cut the same shapes out of the second sheet.
Step 2: MAKE a STENCIL
Then on the paper, draw the elements of the mask and cut everything out
This will now be your stencil.
Step 3: APPLYING PAINTERS TAPE
Temporary tape the stencil to one of the Cor-Plast Ovals.
With the Xacto Knife, cut the the blue tape in the areas that are stenciled. (be careful not to cut through the Cor-Plast)
Remove stencil, then remove the blue tape from the areas that will be painted black.
Repeat with other Cor-Plast Oval.
NOTE: If you feel uncomfortable cutting the tape directly from the stencil, trace the blue tape with a marker. Then remove the stencil and cut.
Step 4: PAINTING BLACK AREAS
Paint ONLY the blue-taped side of both oval mask shapes. (This should take a couple coats)
Hold up to light after each coat to make sure the black areas are solid.
Once dry, carefully peel off all of the blue tape.
Step 5: PAINTING YELLOW & BLUE AREAS
Use enough coats of enamel so you can see the yellow and blue colors well when held in front of a bright light.
Step 6: DRILLING HOLES FOR BOLTS
With the drill, place 4 holes though both pieces. (left side, right side, top and bottom)
Make sure the holes are just wide enough to fit the bolts.
NOTE: for the left and right holes, be cautious to leave room for the outside side panels in the next step.
Step 7: EPOXY THE SIDE PANELS
Apply epoxy to the edge of one side panel and quickly apply it to the back side of one oval mask.
Stay on the outside of the drilled hole. (be careful to leave enough room for the bolt/washer)
Hold them tight against each other until semi-dry, add more epoxy if needed.
Then do the same to the other side panel.
Step 8: EPOXY THE OTHER MASK
Hold tightly against a flat surface, apply more epoxy if needed.
Step 9: SECURE WITH BOLTS
While epoxy is still drying, insert all bolts/washers/nuts.
A washer and nut should be placed at every hole on all sides (inside and outside)
Tighten everything and make sure it feels secure.
If there are any areas on the side panel you think need more epoxy, add it.
Let epoxy finish drying.
Step 10: SEAL EDGES OF COR-PLAST
Apply small pieces of black duck tape to the exposed edges of each oval masks.
Continue all around until it's completely sealed.
(I also added black duck tape to the outside side panels simply because I didn't want to paint again)
Step 11: GIVE THIS MAN a BEARD!
With black duct tape, secure them to the inside of one mask.
NOTE: Be cautious not to cover the translucent areas inside the mask
Step 12: MAKE INSIDE REFLECTIVE
Also add smaller pieces to the non translucent areas on the inside of the masks.
This will help reflect the LED lights that will be added in the next step.
Step 13: LIGHT IT UP!
With black duct tape, secure the battery pack to the top inside of a side panel. (make sure it's on there good)
Then take the string of LEDs and wrap them around all of the bolts on the inside. (if needed, secure with tape)
Step 14: SECURE TO FLAG POLE
Run the pole through the inside of the mask.
Attach the small carabiner to the top bolt of the mask and connect it to the top loop of the flag pole. (this is used as a failsafe)
While pulling the mask down to keep the carabiner taught, secure the top bolt to the pole with a paracord using a Square Lashing knot. (http://www.animatedknots.com/lashsquare/)
With the other paracord, do the same to the pole and the bottom bolt.
Step 15: STRESS TEST IT
If it's wiggling too much, take it down and tighten the knots or increase your paracord length.
Step 16: DONE
Total weight is about 6 lbs.