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.
- 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
- Craft paints with a glossy finish (Red, Blue, White, Black, Yellow, Silver)
- Glue gun
- Scotch tape
- 2 boxes of Laser Finger Beams
Step 1: Remove Foam Tube From the Nylon Disc
- Remove the nylon material from each disc using scissors
- 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:
- The top right corner of the front of the rectangular foam block.
- The top left corner of the front of the rectangular foam block.
- The top of the left side of the rectangular foam block.
- The top of the right side of the rectangular foam block.
- The base of each foam cones.
Step 3: Assemble the Foam
For the wings :
- Pass the left end of the foam tube into the top left corner hole on the front of the rectangular block.
- Pass the left end of the foam tube into the base of the left cone.
- Pass the right end of the foam tube into the top right corner hole on the front of the rectangular block.
- Pass the right end of the foam tube into the base of the right cone.
- Connect the foam tube together.
- Move the cones until they are aligned.
- Add glue on each hole and let it dry.
For the windshield:
- Pass the left end of the foam tube into the left side hole of the rectangular block.
- Pass the right end of the foam tube into the right side hole of the rectangular block.
- Move the foam tube until making a perfect circle.
- Add on each hole and let it dry.
For the console:
- Cut two pieces of foam about the size of a joystick.
- Glue the joystick pieces in the back of rectangular block leaving a good amount of space between them.
- Cut a piece of foam about the size of the gap between the joysticks pieces.
- Glue the gap piece between the joysticks.
- Cut a piece of foam the same length as the 2 joysticks pieces and gap piece
- Glue the piece of foam on top of the joystick pieces and gap piece.
Step 4: Cover the Foam
- Cover the foam with paper mache (see recipe below) and let it dry.
- Sand the imperfection using a medium grit sand paper.
- Cover the foam with a second layer of paper mache and let it dry.
- 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
- 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.
- Stretch the garbage bag on all sides until there is no wrinkles.
- Staple the garbage bag behind the foam tube and on the top of the rectangular foam block.
- Cut the garbage bag excess around the foam tube.
- Add paper mache to cover the staples.
Step 6: Build the Skeleton Face Template
- Download the template (see first image)
- Open the file in Microsoft Paint.
- Go to Print > Page Setup menu option.
- Select the Adjust To option and leave it at 100%
- Click OK button.
- Assemble all the pages using scotch tape.
- Cut the skeleton shape.
- Cut the skeleton eyes and nose.
Step 7: Build the Skeleton Face
- Place the skeleton template on a large sheet of cardboard.
- Secure the template using scotch tape.
- Trace the shape of the skeleton using a pencil.
- Remove the template.
- Cut the skeleton shape using scissors and a knife.
- Trace the outline of the eyes and the nose using a black marker.
Step 8: Paint
- Apply 2 coats of glossy blue paint on the foam pipe surrounding the windshield.
- Apply 2 coats of glossy yellow paint on the body exterior.
- Apply 2 coats of glossy silver metallic paint on body interior.
- Apply 2 coats of glossy red paint for the joystick
- Apply 2 coats of glossy red paint on 1/3 of each wing.
- Apply 2 coats of glossy blue paint on 1/3 of each wing.
- Apply 2 coats of glossy white paint on 1/3 of each wing.
- Apply 2 coats of glossy white paint on the skeleton.
- Apply 2 coats of glossy black paint on the skeleton eyes.
Step 9: Add the Skeleton Face
- Apply a coat of glue on the back of the skeleton face
- Position the skeleton face on the body.
- Put clamps and let it dry.
Step 10: Add the Dr Wily Logo
- Download and print the logo (see first image)
- Cut the logo using scissors.
- Glue the logo at the center of the skeleton nose using a glue stick.
Step 11: Add the Lights
- Glue 2 red finger beam lights behind of skeleton face using a glue gun.
- Glue a blue finger beam light behind the windshield.
- Glue various colored finger beam lights in the body interior
Step 12: Add the Support
- Add a rope on the left side and do a knot on both sides
- Add a rope on the right side and do a know on both sides