For those of you who don't know who Ratchet is....well i'm sorry you lead a deprived existence. Ratchet and Clank is a video game series that my son is batsh#t crazy about. Pictured is Ratchet in his Hyperflux armor. This is what my son wanted to be for Halloween. Since he has been a good sport and worn the same "out of a bag" Super Mario costume for the last 3 years I decided to oblige him.
Part 1: The Helmet
Warning: For the duration of this Instructable I'm going to assume the reader (you) knows a little about the R&C series, because why else would you want to know how to make a Ratchet costume.
Helmet Material List:
Foam floor mat
Electroluminescent (EL) wire
Two part epoxy
Helmet Tool List:
Step 1: The Helmet Begins
Ratchet is a Lombax. A furry faced, weasel-dog looking squishy (non-robot). I am not a puppet maker, and I didn't want my son walking around in a wrong-looking furry mask. This is why he and I decided on trying to recreate the Hyperflux armor. It is one of the only armor upgrades that fully covers Ratchet's face. (Note: R&C Deadlocked is dumb so I don't count that)
To begin, I purchased a bargin basement motocross helmet from Amazon.com for about $40. I probably could have gone out and found a used one for cheaper, but the outdoors and contact with other people frightens me. I will be modifying the helmet a bit so it was necessary to remove the foam core. This was surprisingly easy, which I guess is why this particular helmet was so cheap. The foam just slid right out the bottom of the helmet in one piece.
Next, I needed to size the ears. I took a piece of wood and freehand drew a couple ears until one looked right. I cut out two different size ears and layered them to give it a little more depth so they wouldn't look like wooden ears glued to a helmet.