This year I decided to brainstorm early to figure out what I wanted to be for Halloween, instead of figuring it out two days beforehand. With the new Tron Legacy movie coming out soon and my love of the first Tron movie, I decided that It would be awesome to build a costume based on the new movie. I chose to build the helmet for the character CLU simply because I found it to be the coolest looking, in my own opinion of course.
This project Is fairly cheap until you decide to buy the EL wire and since I purchased 30' (I plan on making a suit as well) of the stuff, it cost a pretty penny. As for the actual building materials, I think I came in around a good $60. The rest, as with any project, is just a whole lot of time and elbow grease.
Step 1: Gathering Supplies
The supplies list is fairly straight forward and comes from my own gathering searching through instructables and seeing the many different ways people have gone about the process of making different styles of helmets.
Thin Cardboard (I used the tops of pizza boxes, anything works as long as its thin)
Bondo body filler
Thin plastic for a visor (mine came from a pair of headphones packaging)
El wire (around a foot a the least)
Car window tint (Black)
Paint (I used auto body paint from Autozone)
Lots and Lots of Sandpaper:
Ranging from 320 grit through 2000 grit
Iron (you'll understand later)
Latex gloves or alternative
Mask of some kind
Epoxy (two part)
Super glue gel