Metroid helmet takes Halloween costuming to a higher level

Hackaday writer [Ryan Fitzpatrick], aka [PlatinumFungi], recently put together this amazing Metroid Power Suit helmet as a prop for a [Mike n Gary], on youtube. How amazing is it? This image is an actual photograph of the helmet! It’s being modeled by [Kelly Johnson], who built a power suit costume for a previous Halloween. But she never made a helmet, which makes sense to us. After all, how are you supposed to talk to anyone while wearing a helmet? Practicality aside, it is a delight to walk through the fabrication process.

[Ryan] started with a motorcycle helmet, making paper templates based on images from the game. After he had a reasonable road map for the work that needed to be done he started cutting away the parts which he didn’t need. The ‘beak’ on the front was then fabricated from paperboard, with the fins on the side sculpted from rigid foam. But there’s still a lot of work to be done from that point. Sure, the internal lighting and colored visor are necessary touches, but it’s the paint job and ‘distressing’ steps that make this look so realistic.

Looks like we’ve exceeded his bandwidth due to the tons of pictures he had of the process. Check out the video after the break.


  1. deadlyfoez says:

    This is f*&^ing cool, I just wish that they added some functionality to it. I’m not talking about speed ball or spring ball, but maybe a ventilation fan and an arduino making some 8 bit sounds.
    Now I know what I want to do for my next costume party… if I have the cash.

  2. supershwa says:

    Holy crap! This is slick! A job well done – the professionalism behind this absolutely stands out!

    Metroid was such a great game…yay nostalgia!

  3. nfritsche says:

  4. Hirudinea says:

    Awesome build, just don’t ride a bike to the party wearing it. (And who knew a bandsaw was the easiest way to cut styrofoam, not me, not owning a bandsaw.)

    • SuperNurd says:

      The easiest way to cut styrofoam is with a heated copper wire, just send enough amps through a thick gauge of solid copper wire and slide the stryofoam through it, or just attach a heating element. This option is basicly a no mess solution.
      If you use this be careful not to touch the wire, it’s not safe, but then again I would not say it is safe to touch a running bandsaw

  5. Anonymous says:

    Great costume, but that must be impossible to see out of in anything less than direct sunlight. :P

  6. zuul says:


  7. andygoth says:

    Unrelated I know, but there’s no way I can see the name Kelly Johnson without instantly thinking of this beauty:

  8. pdadio says:

    Bandwidth Limit Exceeded

    The server is temporarily unable to service your request due to the site owner reaching his/her bandwidth limit. Please try again later.

  9. This is funny. Helmets can be halloween costume.

  10. Stonewall says:

    Am I alone in thinking that video was going to turn into a porno?

    • Stu says:

      I got the porn video vibe (so to speak) from that production quality too. Let’s hope it does cos that Kelly is a proper blonde hotty! Looks awesome in the green lighting too.
      It really shows too that the helmet was made after the suit, because it’s looking way better quality than the rest of the outfit.

  11. dALE says:

    IS there an updated link? or have they not seen that we slashdotted their site?

  12. Galane says:

    I’d like to see her in a Zero Suit. :)

  13. Zachary says:

    Samus is MUTE. She DOES NOT SPEAK. EVER.

    Please don’t ruin future games for me.

Leave a Reply

Fill in your details below or click an icon to log in: Logo

You are commenting using your account. Log Out / Change )

Twitter picture

You are commenting using your Twitter account. Log Out / Change )

Facebook photo

You are commenting using your Facebook account. Log Out / Change )

Google+ photo

You are commenting using your Google+ account. Log Out / Change )

Connecting to %s


Get every new post delivered to your Inbox.

Join 96,597 other followers