The main tools used to make this were my small Taig benchtop lathe with a milling attachment, benchtop drill press and a bandsaw.
The bandsaw I use is a DeWalt portable saw- I made a vertical stand for it so I could use it as a benchtop saw. I love this saw and it will cut through 1" thick Aluminum plate no problem.
For cleaning up fiberglass and resin castings I use a Makita mini belt sander- an absolutely wonderful tool that saves hours of work compared to hand sanding and grinding.
I also used a soldering iron for the wiring and to make battery packs and various sizes of drills and a 6/32 threading tap.
I usually purchase metals from an Aluminum recycling center near my home but Online Metals is a great supplier.
I buy fasteners in bulk from Bolt Depot. It's unbelievably less expensive than buying them in small quantity at my local hardware store.
For servos and Actobotics mechanical parts I used the following from Servocity-
2×Hitec HS-5085MG servos- Servos used to open and close eye iris
3×Hitec HS-645MG servos- Servos used for main head movements
2×Hitec HS-5585MH servos- Servos used for fan mechanisms on sides of helmet
2×Actobotics 1/2" bore pillow block- Bearing mounts used for eye iris cups
1×Actobotics 1/2" bore ball bearing hub mount- Bearing mount used to support head rotation servo
1×Actobotics 1/2" servo shaft attachment- Hitec servo shaft extension for head rotation servo
1×Actobotics 1/2" bore clamping hub- Clamping hub to mount onto 1/2" servo shaft extension
2×Actobotics 1/2" clamping hub- Clamping hubs to hold iris eye cups
1×Actobotics 6-32 x 1/4" ball links (12 ea/pkg)- Ball links for head and fan servo linkages
1×6-32 stainless steel threaded rod- 12" long threaded rod for making servo linkages
2×Actobotics Aluminum servo arms (single)- Heavy duty servo arms for head movement servos
2×Actobotics Aluminum servo arms (dual)- Heavy duty servo arms for fan movement servos
1×2-56 ball and socket linkage (pkg 6)- Ball links used to make eye iris servo linkages
1x 10-32 thread male rod end bearing- Bearing for the head neck joint
2x iris apertures measuring 37mm OD x 5mm thick- found them on eBay
For the radio I used a FlySky FS-t6 6 channel radio. For under $60 it's pretty hard to beat for a computer radio. If you wanted to make controlled using an Arduino while wearing it you could do that too!
For the eyes I used a Sparkfun FemtoBuck LED driver to power 2 super bright 3W high power red LEDs.
I used an Arduino Pro Mini to alter the radio signal into something the FemtoBuck could recognize.
Other materials used included lightweight fiberglass cloth, fiberglass resin, ProPoxy20 epoxy putty and a few small high strength magnets (purchased from a local hardware store.)