Deadmau5 helmet

I am a big fan of Deadmau5 and after a weeks of research into ideas for my first project I decided that this helmet would be good for my first step into the world of Prop-making. It started out life a 30cm/12 inch mirror ball due to difficulty finding other spheres of the right size, turns out that this was a really good idea(some credit goes to my brother for this). Using the concept model made by deadmau5 himself the holes were marked and then cut using a Dremel.

Both the head hole and the mouth hole were cut using a diamond cutting wheel for the dremel which made light work of the glass panels.

 The ears were next, they were just cut from polystyrene foam insulation with threaded rods attached through the edge. The shape is roughly a circle with an piece cut out matching the curve of the head. I used a piece of the helmet that I cut off earlier to get this shape.

  The ears were then covered with black velvet fabric which was glued into place with a spray glue and sewed around the back edge of the ears to hide the seam.

Holes were drilled into the side and front of the helmet to fit the ears and the lights for the eyes. The threaded rods in the ears were just slotted through the holes and secured on the other side with wing nuts. What you cant see here and I don't have any progress images of is the hard hat used to secure this to your head all that was needed to do to to this was holes drilled in to the sides to match the ear holes and it is attached directly to some of the threaded rods in the ears. Also the mouth had a aluminium mesh with a sheer white fabric to cover it glued into place and allow the wearer to see out.

The eyes were just made of a 4" plastic bauble split in two and covered with a white fabric.

The eyes were secured into place by cutting a groove into the helmet and gluing them securely into this groove. A simple LED circuit added to make the eyes light up and this Deadmau5 helmet is finished.

Hope you found this helpful. Check out my Instructables Page on building the helmet which goes into a lot more details on materials and the process.