About: check out my helmet!
Hi Guys

I am going to attempt to show you how I made my Daft Punk Helmet and suit from the film Tron.

We go to a festival each year that is mainly fancy dress and this year we had an epic task of making these suits. My helmet was fashioned from a Boba Fett Helmet from start wars and 8 months and about £250 quids worth of modelling gear.

The main materials used for this were:
  • Black sticky back vinyl
  • 2 x light strips for eyes
  • 4mm plasti card for face sculpting and ear pieces and head band across the top
  • Asetate sheet for eye visor
  • blue cable for rear of head
  • lots of araldite
  • Silcion, silver
  • sand paper for sanding edges down, wet n dry
  • sticky back mirror sheet - vinyl
  • Modelling foam for ear pieces (first attempt)
  • LED's for ear pieces, single hi power blue 3V
  • Filler spray (melted the foam, spray lightly and build up)
  • Black and Silver spray paint

Step 1: The Original Helmet

The helmet was made from a Boba Fett helmet which i cut to pieces and added some things to change its appearance.

I cut away a lot of the front and replaced it with plasticard and aluminium sheet.

Step 2: Installing Eye LED Strips and Chrome on Top of Helmet

i started by adding the lights to the main eye section as we needed to make sure things fit properly.

I then started to add some chrome sheeting to the top of the helmet to change its colour and texture. I tried to put it straight on to the helmet and it didn't work too well, i had to cut them into triangles and lay them over one another to make them fit better and not overlap so much.

As you can see from creases in this photo, i didn't get it right first time...

Step 3: Cutting Off Boba Fetts Face...

i started to cut away any material that wasn't needed and that was also going to get in the way of any future modifications.

The face piece was then replaced with once sheet of 2mm plasticard and then the aluminium on top of that.

Step 4: Faulty Products!!!

Once the eye piece was fixed into place it became apparent that one of the lights was faulty, so i took it apart again and sent it back to the guy from ebay that sold it me... once done it worked fine.

Step 5: Wires on the Back of Head

The wires were just cut to length and threaded into place to make this affect.

I stuck them down with a little clear silicon, which i put under the plastic at each end of the wire and i also smeared some across the helmet under the wires.

The white strip across the top and around the sides is raised slightly with plastic spacers to enable me to get the wires underneath the edges. All the spaces are held with areledite.

Step 6: Robot Ears

The ear pieces were made with a long strip of plastic bent and fixed in place to create the top curve and a piece cut and fitted to the front, i used the modelling foam to make templates and then fitted the plastic around them. 

Once the plastic ear pieces were put together i covered them with the chrome sheeting and siliconed them to the head, the were a pretty good fit, but i had a little trouble getting them on straight.

The waveform  on the black disc was made from 2mm plasticard. I masked the shape on and then sprayed it black and then lacquered it.

Step 7: Face Piece

Once the aluminium chin piece was fitted i started to apply the black face film and had to apply layers that overlapped slightly to get the smoothest effect possible.

Step 8:

For the visor that covers the lights in the eyes i used very thin acetate sheet and then tinted it with tinting film.

I worked very well and hid a lot of mess around the eye cut out. it also dimmed the lights down just enough as they were super bright without it.

Step 9: Tidying Up

Once the majority of the work was done, i sprayed the inside of the helmet black to neaten stuff up.

Step 10:

For the gloves i sketched out the shapes of the plates on the back of the glove.

I covered some plasticard in chrome sheet and then cut the pieces out.

They are attached to the glove using areledite, i tried silicon but them just peeled of as they were too smoother surface.

Step 11:

I went around the helmet and filled any gaps with silver silicon and then smoothed them all out, this really made the helmet strong and looked smooth.

The lights were run using a 12v 8x AA battery holder with a jack plug connector going to the helmet and the suit. The Discs on the back of the suit also ran from the same power supply. 

The Helmets were wired with a separate on/off switch to enable us to leave the suits on and reduce glare from the inside of the visor. it was pretty hard to see walking around a festival at night with the helmet lights on.

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    22 Discussions


    7 years ago on Introduction

    how can you see with blinding LEDs in front of your eyes and between you and the visor surface?

    1 reply

    Reply 7 years ago on Introduction

    The back of the lights are heavily masked with duct tape to block out any light, however the glare from the visor is quite bad at night, daytime is fine.



    Reply 7 years ago on Introduction


    Search for 'LED light strips 12v'

    There is two strips, each folded once to make four layers. It's like a rubber strip that some people stick to their cars lights...

    Hope that helps



    7 years ago on Introduction

    hey man, u know that in alot of songs where they make a robot voice? its a talkbox, like they use for guitar except for a keyboard..... u should get a talkbox, hook it inside the helmet, and have a keyboard with a strap on..... it would give a goood effect....

    1 reply

    4 years ago

    I would really like to make this before Halloween but I can't find the boba fett helmet you used. Where did you get yours and how much did it cost?


    5 years ago on Introduction

    How did you make the visor?
    Heat gun? Over and form casting of sorts?


    5 years ago

    Can make a video of this


    5 years ago

    You could sell these for a living... :p


    7 years ago on Introduction

    i chromed the helmet and removed all the screws i could find but just can't get it apart did you use a dremel to get the the face apart?


    7 years ago on Introduction

    yeah the cheapest one is this one in america: getting one used can save some money, just change the tube.......