Step 9: Helmet - Step 3: Ear Pieces & Electronics

For the ears I found these perfect rubbery drain covers for like $4. They are supposed to protect your drain from hair going down it.

Drain covers
White Fabric
Fabric Chalk
Spray Adhesive
Rubbermaid 1 cup Twist top containers
Green LEDs
4 AAA Battery Pack
Red & Black wire

Hot Glue Gun
Palm Sander
Soldering Iron

I had to prepare the drain covers by using my dremel to sand off all these little nubby things sticking out of it.  Then I laid the white fabric on top of them and used the fabric chalk so I could cut out the pieces.  Next, using the spray adhesive I attached the fabric to the drain covers.  I added hot glue in places that needed more hold.

The drain covers where so perfect, they even had holes to mount the LEDs in.  I put the LEDs in place and added hot glue for stability (so the LEDs would be facing straight up).  I soldered on some red and black leads to the LED for later installation.  I then cut out the bottom of a small round plastic container, specifically 1 cup Rubbermaid Twist tops.  I sanded them down on both sides (I like this foggy look).  Put hot glue in the hole of the drain covers and dropped the sanded container bottoms into place.

To install, I cut the red fabric from around the hole I had previously drilled into the helmet, and hot glued the red fabric down.   I punched a hole through the styrofoam so the wires from the LED had somewhere to go.  I hot glued the ear pieces to the red fabric so they would sit flush and not fall out.

Next I wired everything up. I needed one resistor at 27Ohms and the switch and battery pack.  For the battery back I cut out a rectangle shaped box out of the back of the helmet in the foam.  This allowed more than enough room for the batter pack.  I didn't glue it in place since the black fabric that came with the helmet would keep it from falling out, and I would need a way to take the batteries out.  The switch just sat in front of the batter pack.  I soldered everything together and hid the wires.  This ended up coming out looking very clean, and I was quite happy with the results.

How much did this run you total? Also, did you consider sculpey?
Proto man and mega man are cool
I am SO being Proto Man next halloween.
You're instructable has helped so much with my protoman cosplay. It's radically different varient of protoman but nonetheless your instructable helped a lot dude. I was overengineering my stuff (like the boots and buster). You've inspired me to post my construction of my metal protoman shield. And yes I am crazy enough to lug one around a whole con weekend.
Awesome! Glad to hear it. Let me know when your stuff is up on instructables, would love to see it!
This is E.P.I.C. for: <br>E xcelent <br>P leasent <br>I ncredible <br>C ool/N/awesome
Wondering if you could make a youtube video of this process? or a step by step procedure :D
Ok I know you were trying to make it simple on this but what i would've done is make a switch where everytime you press it one by one the LED's on the power bars i guess you could say would shut off making it look like Protoman was losing power
you can also sew the 2 parts of the shield
amazing! i saw this on revision3 destructoid btw...you should check it out
Thanks :) Yeah, I saw that too. I kind of do this every year on their site.
Always a &quot;mega&quot; winner. Great job. :) Looking forward to watching your latest video of your parade of costumes.
woooooowwww!! i love it!!
Nice job! Megamans got to stick together!
Nice :) I saw yours yesterday! Love the solution!
haha, that was awesome...<br>
This inspires me to make one in my size so badly, once actually tried to make a heat man costume. witch kinda failed.
The helmet looks like it'll last him quite few trick or treats haha, the rest of the costume might need to be redone in the future tho.
It's actually a small youth motorcycle helmet with lots of padding on the inside. It's the right size. Just looks a little bit as a proto man helmet. I actually kinda like the look, it reminds me of powered up.
Oh I didn't see the padding, but if you got some of that out it will last a while, it looks like I wouldn't have much trouble getting my head in there haha.
Epic costume is EPIC!!!!!
This is awesome! Also, I have a question for you. Were Protoman and Megaman both 'good guys'? Been a while since I played Megaman. :)
Thanks! If I am remembering correctly, he was mostly good with a couple of lapses.
awesome, thanks :)
for future referance protoman was created by dr light for the war way before megaman. sadly he lost his memory and is much more powerful than megaman. he has never been evil, the protomen you fight in megaman every now and again or clones made by wily. but aside from that, your plans look awsome great job, i cant wait to start building!!!!
Damn, thanks, yeah I forgot that they were clones. I knew that Proto Man came first, hence why the oldest son is wearing it.
So freaking great! Fantastic job, once again.
And thank you once again ;)
Once again, another insanely well-done costume... I love the all the ingenious things you've done with regular materials. So cool. <br><br>I just can't let my kids see this... &quot;Gee, Dad. Why didn't you make something like THAT?&quot; (I went down the quick and easy road this year.)
Totally awesome!!!<br>I liked the Mega Man costume, but there's nothing better than a costume of a wonderful and awesome looking side character!<br><br>You should enter this in the Halloween contest! It's quite a nice and simple design, along with looking AWESOME!!!<br><br>The only thing is, you should have a yellow scarf to go with it to &quot;complete&quot; the look. Make sure it's thick. Or use a long yellow bandanna. That might work too.<br><br>Great job!
Thanks for your comments. It has been entered in the contest. There is a yellow scarf, it's just not in that main shot ;)

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