This is my wife wearing the Thomas costume as she recently became a Daft Punk fan since their appearence in TRON movie.
Here i made the helmet using cardboard only (yes carboard, NO mache at all) with a new technique i developed to make perfect spheric surfaces with very thick cardboard. The gloves are my wife's work using thermoformed EVA.
The 80 leds were simulated using semi-transparent resin, there are only 10 ultra high intensity leds inside the helmet.
UPDATE:
Now you can download all of the files needed to build it at
[link] everything is in there. Enjoy the papercraft.
I have one question. What did you use for the visor?
by the way, i have a one technology, to make it out of epoxy.
Apply 3 coats of water diluted white glue (50%-50% mix) this make the opaline cardboard shine. I let the white glue dry on every coat (yes you must be patient). Then just use metallic spray paint.
And there you are, that's why you need thick cardboard or it wouldn't survive such a process. And now that you know i'll have to kill you and all of my readers hahahaha! ... nah! just kidding, enjoy the knowledge.