In this instructable you will learn how to make a Dr. Who TARDIS Hat
I made it at TechShop. Check out TechShop here.
Please check out my other instructable (Coming Soon) for information about how to make a TARDIS jacket.
TARDIS blue spray paint
TARDIS blue ribbon
A Small Speaker
Step 1: Design
I built my vector files in Corel Draw. You can use any vector program you prefer. These will either be used to run the laser cutter, or as a mask for cutting out the pieces by hand.
Step 2: Prep Materials for Construction
Sandblast the acrylic tube until it looks like the photo. This will give it a frosted glass look. Make sure to sandblast both the inside and outside of the tube. Some plastic suppliers will do this for you, many won't. They also might stock frosted plastic tube.
Cut the flat cardboard using vectors and a laser cutter. Alternately, if you have mad crazy exacto-knife skills, you can cut it out by hand. Once you have all of the pieces cut out, bevel the edges so that they can fit together with the other pieces to make a box easily.
Cut the cardboard Tube using vectors and a rotary attachment for the laser cutter. This one is a little more difficult to do by hand. Try cardstock if you want to cut it by hand, to avoid accidentally cutting yourself when the exacto-knife breaches the cardboard tube.
Cut the vinyl using a CNC vinyl cutter, and the vectors you designed. Alternately, if you have mad crazy exacto-knife skills, you can cut it out by hand.
Transfer the vinyl to the acrylic pieces.
Step 3: Assembly and Paint
Tape everything together. Using superglue, glue all of the pieces together internally, except for the top circle. If you have the time, use an epoxy, and let the glue set overnight.
Once the glue has set, remove the tape. This will give you a smooth outside surface to paint on. Spray paint the cardboard, making sure to coat all visible edges.
Insert the acrylic tube and glue on the lid.
Note: I adjusted the size of my cardboard and acrylic tubing once I had it taped together. You can see the scale difference in the two pictures below.
Step 4: Program
I am using the Arduino platform to program the hat.
Simple code can be found at arduino.cc.
I have 2 LEDs and a speaker.
One LED pulsed with the whine of the TARDIS that was produced by the speaker.
The other was simply a backlight for the Police Box Vinyl/Acrylic pieces. 4AA batteries and a lillypad completed my tech.
Step 5: Add Ribbon and Wear It!
Video will be uploaded soon. You can attach the hat with ribbon, a headband, or some other hair accessory.