Typically, when people hear that you’ve made a Halloween costume for your dog, the statement is met with the eye rolling and polite lies about how cute the outfit is. There are few exceptions to this rule, and [Dino’s] latest creation is one of them. For this week’s entry in his Hack a Week series, he created a “Headless Horseman” costume for his dog [Sophie].

The costume borrows parts from one of his previous hacks, the Hexababy. Reclaiming the dismembered head from the disturbing crawler, [Dino] reattaches it to the doll’s body, just not in the traditional manner. He screws the baby’s head to the arm of the doll after fashioning its outfit from some scrap cloth. The doll’s head retains it’s beady red LED eyes from the previous project, but [Dino] added a tilt switch to the setup so that they light up sporadically as the dog runs about.

Be sure to check out the video below to see the final result of [Dino’s] work. The doll looks great, though it seems that its saddle needs some reinforcement to handle [Sophie’s] bountiful energy stores.

Halloween is the time of year where you can dress up as a pirate, muppet, or superhero and no one will bat an eye. During this holiday of expanded social permissiveness, [Nbitwonder] decided that building an Arc Reactor from Iron Man would be appreciated by his engineering cohort.

The ‘body’ of the reactor was manufactured on the RepRap Mendel we covered from beginning to end. A few minutes with Google Sketchup was all that was needed to generate the files and send them to the printer. In a few short hours, [Nbitwonder] had the body of his Arc Reactor.

The board design was thrown together in Eagle and etched. 11 blue SMD LEDs were thrown into the mix along with some borrowed resistors. Pieces of a hard drive spindle and a little bit of wire rounded out the parts list, and everything was assembled with the DIYers favorite tool, the hot glue gun. Not a bad job for a few hours of work.

The files for the Arc Reactor are up on Thingiverse along with a Flickr photoset.

When it comes to Halloween costumes, [Michael] doesn’t like buying expensive and poorly made bits of cloth and fabric that resembles [random Disney character]. Last year, his son decided to be a robot for Halloween and although gray spray paint and dryer vent hose make a very good costume, that only goes so far. The robot needed lights, so [Michael] spent a little time on this build that blinks a few LEDs in a random pattern.

The build is very simple; an ATtiny13 drives two 74HC595 shift registers. The code – all 30-odd lines of it – uses the random() function to shift high or low values to the shift registers. After pausing for a little bit, the cycle continues and a new patterns of LEDs light up.

The electronics of the robot costume could be easily transferred to another theme – astronauts need LEDs on their backpack, and of course aliens communicate with blinking lights. In any event, it would avoid last year’s fiasco with a dozen [Heath Ledger] Jokers. Check out the video of [Michael]‘s intergalactic robot son after the break.

[Andrew Ainsworth] has been making and selling costumes based on Star Wars character (some original, and some of his own creation) for several years. Lucasfilm sued him for $20 million back in 2004 claiming infringement of intellectual property rights. He stopped selling them in the US (as it was a US copyright) but now the UK Supreme Court has ruled in his favor, siding with his claim that the costumes are functional items and not works of art.

Good for him, but copyright issues aren’t what interests us here. The BBC clip showing him using a vacuum former to make the Stormtrooper helmet really caught our attention. A bit of further searching led us to find the thirteen minute video after the break showing the entire process, from sculpting the mold by hand, to forming the components, and the final assembly seen above. It’s a fascinating process that makes use want to build our own vacuum former (preferably on a larger scale than this one). It would come in handy whether it’s Star Wars, Daft Punk, or any number of other projects you’ve got in mind.

[Thanks Danny]

Here is a post from [John's Projects]. For the insane, satirical, and incredible 2011 Omaha Groundhog Prom [John] and his buddy fabricated  helmets reminiscent of our favorite robot rockers.  [John] needed something harder, better, faster, stronger than the competition and wound up creating LED matrices that mount behind aerodynamic motorcycle helmet visors.

The helmets were constructed in about a weeks time and in a similar fashion to the real helmets. [John] sourced some cheap motorcycle headgear and mounted the LEDs, their driving transistors, and ballast resistors to a 1/32″ (flexible) plexiglass sheet that sits face to face with the wearer. [John] walks through the whole process starting with a half inch grid drawn onto a paper template. The template is cut from the plexi using tin snips, then LED holes are carefully drilled in the thin plastic using various bits up to 13/64″. The 90 some odd LEDs are, one more time, fitted then hot glued in place and soldered in vertical columns to simplify things and prevent any short circuit. An Arduino Pro (via common emitter 2n2222 on/off circuits) provides some digital love to the 18 LED columns and is connected to a Velleman Sound-to-light kit which modulates the brightness of the whole visor based on da funk. Two pots are also wired to provide sensitivity and pattern selection to the human after all.

We can’t imagine the technologic setup is fresh after being subjected to the steam machine, high life, and whatever else for too long. Oh yeah, Some brighter LEDs could give the helmets night vision and make the whole thing come alive with emotion. Something about us is burnin to know what powers the helmets. Nice work [John]!

Check out some videos of these superheros rollin’ & scratchin’ after the jump!

The Halloween hacks are rolling in late this year, but we’re delighted to see that [DJ Sures] finished his borg costume in time. It is made up of a hodge-podge of items from different cultures… oh wait, so are the borg. These include a set of hockey pads spray painted black with just a light misting of silver to give them some depth. After taking the image above (which mostly shows off his makeup) [DJ Sures] added an LCD screen to the chest plate and lighted electronics throughout. See for yourself after the break.

If you liked this you might take a look at his singing spark plug.

Here’s a strange one. This fighting game uses a video game interface to instruct modern-age gladiators on how to bring the pain. The costumed fighters cannot see anything other than a set of lights in their helmets instructing them to move or punch. A camera films them and overlays the footage on a digital background along with simulated blood and a health bar for each. NES controllers are used to instruct them, and switches inside the costumes register the pummeling they receive and deduct health accordingly. This wouldn’t be any good without a demonstration, which we’ve embedded after the break.

[Harrison Krix] finished his Daft Punk Helmet replica and posted about it this week. We took a look at his work back in October but he’s come a long way to pull off a legendary build. Take three minutes after the break and see 17 months worth of work. So many skills were pulled together to make this happen; sculpting, mold making, painting, electronic design, mechanical design, and bad-ass-ery. Crammed in along with your noggin are a bag-full of LED boards but the Arduino that controls it all resides outside, in a project box tethered to the helmet. This is a masterpiece of socially-unwearable geek fashion.

[Thanks Eric & Kirov]

Ask any engineer what originally sparked their interest in technology, and almost universally the response will be a Hollywood film or TV robot — Star Wars’ R2-D2, the B9 robot from Lost in Space, or Short Circuit’s Johnny 5, to name a few. Engineers need a creative outlet too, and some pay homage to their inspirations by building elaborate reproductions. At this year’s Maker Faire, droid-builders had their own corner in the center hall, their work ranging from humble craft materials to ’bots surpassing their film counterparts in detail and workmanship.

Probably the most beloved film robot of all time would be R2-D2, and probably the best-known reproductions originate from the R2-D2 Builders Club, who’ve been profiled in Make and Servo magazines, among others. Every kid’s dreamed of building their own R2, perhaps from a wastepaper basket and scrap, but the club’s astromech droids are anything but kid stuff, with machined aluminum domes and intricate motor and sound systems. The club doesn’t sell robots — that would infringe on trademarks — but they do share techniques and component plans. The finished droids (are they ever really finished?) put in appearances at fan conventions and charity events.

Danger Will Robinson! Career inventor [Andrew Filo] has been engineering practical everyday items for three decades, but he cuts loose by bringing his early inspirations to life. His carefully-researched reproductions include an Apollo-era NASA spacesuit and a talking, walking…er, rolling…B9 robot.

Self-described recluse [ELS] is a builder and collector of film props and reproductions. Though he insists his Robby and B9 aren’t perfectly canon, you’d never know by looking; the detail and finish on these two was amazing. Robby is wearable, and periodically through the weekend he’d climb into the suit and entertain a new generation who otherwise might not be acquainted with this Hollywood classic.

[Matthew Ebisu] is obsessed with all things Pixar. As one of the younger makers exhibiting, [Matthew’s] materials may be simpler, but his enthusiasm more than fills the gap. He’s built — and launched — Carl Fredricksen’s house from Up in miniature form. It didn’t quite reach South America, but did net him a pen pal in Nevada. His Autopilot and Eve droids from Wall-E are more craft than tech, so his latest project, along with a gaggle of like-minded friends on his D.I.Y. Pixar fan site, is to develop a working Wall-E robot.

So readers — is there a favorite Hollywood ’bot to credit for your passion for this hacking madness? And have you built one yet? A HAL-9000 in your kitchen? Tell us about it in the comments, or if you have a build log posted online somewhere, drop us a link at tips@hackaday.com.

[Scott Holden] went all out this year and built an amazing Tauntaun costume. The Tauntaun from Star Wars was massive,  standing 8 feet tall, and usually carrying a rider. [Scott] wanted to make it the correct size, and ultimately pulled it off. He had to build custom stilts to get the leg angle correct as drywall stilts were too straight. The rest is mainly pvc and fur.  We think he did a fantastic job on this. The effect is quite nice, and we can imagine that in person it is even better.

Take note at the bottom of page 3. Apparently, he got pinned in the costume in his workshop and almost had to spend the night on the floor in the costume. That’s pretty wild, at least he was warm.

[via makezine]

[creatrope] sent in this slick Alien costume that he made for his son. The costume does look decent, but not professional. For something tossed together from parts around the house, it looks fantastic. The real kicker, is the fact that it has the retractable inner mouth. The retractable mechanism is constructed from Legos and extends when his son opens the mouth. We think he did a fantastic job with this costume, but if you’re looking for something a little more polished, check out this Alien made by [Asy0uw1sh ] you can see a little more detail on how it works here.

For all their varied and entertaining uses, circuits and code comprise only part of the complete hacking experience. To really put your project over the top, sooner or later you’ll want to possess some physical fabrication skills. Consider the works of [Ben Heckendorn]: He’s always done a fantastic job with the electronics, but it’s the fit and finish of the enclosures that make him a legend.

“Fabrication” usually conjures images of shop tools — saws and sanders and drills — all tremendously useful skills worth learning, and easily within reach of most home shops or garages. Recently, the techniques of mold making and casting have seen something of a DIY renaissance. Mold making is nothing new, the basic concepts go back millennia, but in just the past few years the materials for extremely high-quality molds have become safer, simpler to use, and easier to acquire.

This being Halloween month, what better example of the medium than this impeccable replica helmet styled after half of the musical duo Daft Punk (a recurring theme among Hack a Day contributors), created by prop maker [Harrison Krix]. After sculpting an original master part (from common hardware store and art store materials, we might add), a one-piece flexible mold is built up from silicone, which captures every minute detail, and later the helmet form is cast from a thin layer of resin. The visor is vacuum formed. A follow-up with the internal electronics build is yet to be posted, but even at this stage the shell alone is so refined it looks straight off a showroom floor. If mold making can do this for someone’s noggin, imagine what it can do for your next creative hardware project. Smooth-On, a major supplier of these materials, has a free PDF introduction and a set of tutorials on their web site.

[thanks Wolf]

[derektroywest] has posted a detailed step by step breakdown of making a Daft Punk costume. They’ve done a great job, the overall look is very convincing. They include links to where to get each part as well as information on how they pulled it off. The helmets were inspired by the timelapse Daft Punk helmet build. As you can see in the video, they don’t have the entire visor made into a display, but the effect is quite nice, especially because it is multi color.

We love all of the creative Halloween costumes that have started trickling in now that the holiday is finally over, and people have found time to document their last minute projects. Take this functional Etch A Sketch costume made by [mazinbenny]. The knobs are lawnmower wheels. The pulley system is strung with 1/16″ wire rope to move a carrier for a dry erase marker. The marker draws directly on an acrylic screen. HowStuffWorks has a post on how a real aluminum powder based Etch A Sketch works.

We’ve covered more technical Etch A Sketch projects in the past. We’ve seen them hooked up to computer mice, drawing portraits at Maker Faire, and commenters have even suggested turning mechanical dry erase boards into giant Etch A Sketches.

[Matt Daughtrey] sent us this sweet little project he’s doing for Halloween. He’s building some animated LED eyes. He says that the whole thing is 3 individual LMDriver platforms, another project he’s working on. There isn’t any info available about that, but he does expand a little. He states that each display module uses an Atmega169 with some heavy multiplexing.  The eyes really don’t look that impressive sitting on the bench, but watch the video to see how cool they really are.

We noticed that the back of the boards appear to have http://www.embeddedether.net on them.  Unfortunately that site seems to have been grabbed by a domain squatter.