I never tire of seeing how different builders tackle the same costume, and Optimus Prime is one of those characters people keep creating in new ways. Instructables user dannyeruena loves Transformers and funneled his passion into making this fantastic costume. He only spent about $40-50 on the costume, and it looks slick. The material he used the most of was cardboard and he was able to get at least some of it by recycling material from local markets. Here’s some info on making the head:
First select an old bicycle, snowboarding, or hardhat helmet that you never plan on using again.
From the Cardboard or foamboard
– Cut 2 ear flaps (Triangle shape)
– Cut 1 center unit piece (Retangle Shape)
– Cut 2 side discs where you plan on attaching the 2 antennae. (circle discs) Antennae.
Like most of this project it will be a series of trial and error to make things fit, the ear flaps are no exception. Once you have your desired shapes cut out, you’ll need to cut circles on the inside to affix to the helmet with hot glue. Adjust fast because the glue dries quick.
The Center unit will present the biggest challenge as the concave center will need to be cut out with your best estimate then refitted for additional cuts. Remember don’t over guess because you can always take off more, but you can’t regrow once cut. Take your time on this fitting, it will pay off in the end.
Read more at Instructables.