Dr Wily Machine

Here's my take on building a Dr.Wily Machine. This was my Halloween 2016 project I build for my girlfriend costume and its loosely based on this drawing.

Materials required:

• 2 x 8 7/8'' foam cones
  
• 2 x Large nylon disc approximately the size of your waist
• 1 x Thick foam rectangular block. (I ended up using a piece of foam I had left over from a shipping box, but you could probably use a form cube and cut it in half.
• Various sizes of Styrofoam rectangular blocks. (Again I used left over pieces of foam but you could probably used the other half of the cube to accomplish this.
• 1 x Large blue garbage bag
• Newspaper
• Flour
• Craft paints with a glossy finish (Red, Blue, White, Black, Yellow, Silver)

Tools required:

• Glue gun
• Drill
• Scissors
• Knife
• Stapler
• Pencil
• Scotch tape
• Clamps
• 2 boxes of Laser Finger Beams

Step 1: Remove Foam Tube From the Nylon Disc

1. Remove the nylon material from each disc using scissors
2. Disconnect the foam tube from each disc.

Step 2: Drill Holes for the Foam Tube

Drill a hole about the size of the foam tube at each of the following locations:

1. The top right corner of the front of the rectangular foam block.
2. The top left corner of the front of the rectangular foam block.
3. The top of the left side of the rectangular foam block.
4. The top of the right side of the rectangular foam block.
5. The base of each foam cones.

Step 3: Assemble the Foam

For the wings :

1. Pass the left end of the foam tube into the top left corner hole on the front of the rectangular block.
2. Pass the left end of the foam tube into the base of the left cone.
3. Pass the right end of the foam tube into the top right corner hole on the front of the rectangular block.
4. Pass the right end of the foam tube into the base of the right cone.
5. Connect the foam tube together.
6. Move the cones until they are aligned.
7. Add glue on each hole and let it dry.

For the windshield:

1. Pass the left end of the foam tube into the left side hole of the rectangular block.
2. Pass the right end of the foam tube into the right side hole of the rectangular block.
3. Move the foam tube until making a perfect circle.
4. Add on each hole and let it dry.

For the console:

1. Cut two pieces of foam about the size of a joystick.
2. Glue the joystick pieces in the back of rectangular block leaving a good amount of space between them.
3. Cut a piece of foam about the size of the gap between the joysticks pieces.
4. Glue the gap piece between the joysticks.
5. Cut a piece of foam the same length as the 2 joysticks pieces and gap piece
6. Glue the piece of foam on top of the joystick pieces and gap piece.

Step 4: Cover the Foam

1. Cover the foam with paper mache (see recipe below) and let it dry.
2. Sand the imperfection using a medium grit sand paper.
3. Cover the foam with a second layer of paper mache and let it dry.
4. Sand everything using a very fine sand paper.

Paper mache recipe:

Mix together in a bowl the following:

• 1 cup of cold water
• 1 cup of flour

Step 5: Add the Windshield

1. Place the garbage bag on the foam tube by starting from the back and slowly pulling the bag towards the front passing through the foam tube.
2. Stretch the garbage bag on all sides until there is no wrinkles.
3. Staple the garbage bag behind the foam tube and on the top of the rectangular foam block.
4. Cut the garbage bag excess around the foam tube.
5. Add paper mache to cover the staples.

Step 6: Build the Skeleton Face Template

1. Download the template (see first image)
2. Open the file in Microsoft Paint.
3. Go to Print > Page Setup menu option.
4. Select the Adjust To option and leave it at 100%
5. Click OK button.
6. Print.
7. Assemble all the pages using scotch tape.
8. Cut the skeleton shape.
9. Cut the skeleton eyes and nose.

Step 7: Build the Skeleton Face

1. Place the skeleton template on a large sheet of cardboard.
2. Secure the template using scotch tape.
3. Trace the shape of the skeleton using a pencil.
4. Remove the template.
5. Cut the skeleton shape using scissors and a knife.
6. Trace the outline of the eyes and the nose using a black marker.

Step 8: Paint

1. Apply 2 coats of glossy blue paint on the foam pipe surrounding the windshield.
2. Apply 2 coats of glossy yellow paint on the body exterior.
3. Apply 2 coats of glossy silver metallic paint on body interior.
4. Apply 2 coats of glossy red paint for the joystick
5. Apply 2 coats of glossy red paint on 1/3 of each wing.
6. Apply 2 coats of glossy blue paint on 1/3 of each wing.
7. Apply 2 coats of glossy white paint on 1/3 of each wing.
8. Apply 2 coats of glossy white paint on the skeleton.
9. Apply 2 coats of glossy black paint on the skeleton eyes.

Step 9: Add the Skeleton Face

1. Apply a coat of glue on the back of the skeleton face
2. Position the skeleton face on the body.
3. Put clamps and let it dry.

Step 10: Add the Dr Wily Logo

1. Download and print the logo (see first image)
2. Cut the logo using scissors.
3. Glue the logo at the center of the skeleton nose using a glue stick.

Step 11: Add the Lights

1. Glue 2 red finger beam lights behind of skeleton face using a glue gun.
2. Glue a blue finger beam light behind the windshield.
3. Glue various colored finger beam lights in the body interior

Step 12: Add the Support

1. Add a rope on the left side and do a knot on both sides
2. Add a rope on the right side and do a know on both sides