Daft Punk helmets are the sort of items that practically shout a challenge to cosplayers: “Replicate me, I dare you.” Instructables user volpin rose to the occasion and created a sleek and stylish helmet that’s nothing short of impressive. He documented the process and notes it is both a complicated and a lengthy build. The positive is that he explains every part from cutting the blueprints to programming the LEDs in great detail. It looks intense.
The process for making the helmet base:
Using the blueprints, trace out the X, Y, and Z axis planes of the largest sides of the dome onto the 1/4″ MDF, then use your saw (band, scroll or jig) to trim them out. Cutting slots in the pieces to fit them together will assist in the steps to come. Slot the pieces on top of one another and use the wood glue to adhere them into place, then allow the glue to dry. (pic 4)
Trim the polystyrene foam into blocks that fit into the recesses of your MDF form, and glue these blocks together with Gorilla Glue. Allow these to set for 24 hours.
Once the glue on both the MDF form and the polystyrene foam has cured, glue the blocks into the MDF form with more gorilla glue. Don’t worry if it seeps out of the joints, it will all be sanded off soon. (pic 5)
After allowing this assembly to dry, begin to carve out the overall “dome” shape with a coping saw or electric knife. You’re only trying to get the general shape now, so leave it kind of rough. (pic 6)
After getting the “dome” shape close with the rough trimming, follow up with an electric orbital sander and very coarse sandpaper. You can do this stage by hand, but the polystyrene foam tends to “tear” when hand sanding, so I recommend an orbital if you have access to one. This process will be very, very dusty! Wear a respirator! (pic 7)
Full tutorial at Instructables.