I thought id continue the Zelda kick I am on by posting my last year halloween costume. It is for those of you who don't know the wind mill guy, Guru Guru, from the legend of Zelda series.
Step 1: Box
I constructed the boxes out of 1/4" birch plywood. Using a basic cad model i made i got the basic dimensions. I cut out the pieces on a table saw then screwed the parts together.
Step 2: Box Staining and Painting
I then stained the boxes with a dark walnut stain, and spray painted on the design using a template that i printed out.
Step 3: Crank
For the crank i simply bent a 1/2" steel rod, turned a wooden cap out of purple heart and slap it on. I drilled a hole into the side of the big box, added a bearing onto it to hold the rod, and screwed it all together.
Step 4: Piping
I used basic pvc piping to construct the ducts of the costume... not much more to say... it was pretty straight forward cutting and glueing.
Step 5: Test Fit
I tried it on.
Step 6: Dyeing
I used an old pair of shorts and dunked them in some blue dye, as for the shirt i poured some of the blue dye into a spray bottle and sprayed randomly to get the effect i wanted.
Step 7: Internals
I drilled some holes in the sides. Rigged up some holders for the cheapo speakers (so i can blast the song of storms) i installed.
Step 8: Horn
I made a template in rhino that i printed out onto paper, and spray adhesived onto 1/8" styrene sheeting. I put them together using epoxy putty and bondo. Sanded it smooth and viola a horn.
Step 9: Finished
What the costume looks like as a whole... well sorta. I went to a party but unfortunately no pics of the whole thing put together.
(the horn pictured was a temporary one i had made)