(1st Weekend) – Progress on Bobby’s Halloween costume. Seriously, what is this thing!!


So … can you tell now what I’m working on? … Maybe you need to get back in touch with your inner 90’s-kid-playing-playstation-2 … I used to play this game with my brothers in the dark basement at night … It’s always stuck with me since.

photocredit: Wikipedia page
photocredit: TOM PARKER (Character artist) This guy is good!

This year, I’m going for an actual horror movie character. If you haven’t seen the “Silent Hill” movies or played the games, don’t sweat it. The game was fun (as I remember it), the movies were ok. I liked it because I played the games. The character’s name is “Pyramid head” … dunno why …

So, I started with the best part. The head:

To begin with, I purchased a sheet of 1/4″ thick plywood at the “Depot”. You’ll need at least 2 sheets of 24″ x 48″ (that’s what I got). This stuff is ridiculously useful so feel free to splurge.

Now the tricky part. How the donkey do I get the right shapes? I’ve looked online and found nothing decent! a few simple attempts but nothing that will give me a decent looking shape. So I decided to take matters into my own hands. Design it myself on CAD and keep it flexible enough to mold it into the exact shape I want using the images online as a guide. Simple right?

We’ll yes, maybe for me. But I think it would be nice for me to share my work so that you don’t have to waste your time doing the same thing if you wanted to attempt this. Here’s My Solidworks 3D CAD model uploaded to GrabCAD. Feel free to download it.

Here are the simple shapes you’ll need if you don’t want to mess around with the CAD stuff:

Now, here’s something useful I’ve used on many projects. Remember how my worktable is made of full on 2×4’s. I used another piece of lumber and I drill it right into the table for extra support. I love this table.

After you draw the shapes you want on the wood, the Best tool for this Job is a tiny little saw that could! This Dremel Max is really the perfect tool for this job. I bought it from Home Depot for under $100 CAD.

Hard to see here, but I actually modified the guide a little to make the cuts even more flush! This tool advertised flush cuts! But I wanted super flush cuts! so I trimmed back the plastic guides to make that work.
And I also wanted to point out one of my new favorite tools … a digital angle ruler. accurate up to 0.1-degree. Couldn’t have done these shapes without it. Got this one from Canadian tire.
Here’s what you get after all the cuts.

Now that you have the wood cut, It’s time to attach them together. To do that, I use a flat wood joining plate Using my self made bending Jig (2 angle iron’s drilled together) placed in my vice.

And then I use my angle tool again to eye-ball the bend. I get the angles from the CAD file I built. But If you don’t want to get into the file to get the angles, here they are: 5x 71.5deg, 6x 122.1deg, 4x 134.2deg, & 3x 163.6deg (going from front to back … I’m sure you can figure out which ones).

Here’s a few up close pics of the build.

Oh, I almost forgot. I picked up 2x boxes of 100x #6 x 1/2″ long flat socket head particle board screws. I’m running low … you should probably get 300x at least.

Next step, Make it fit well, make it look good, add the mesh & foam. I’m happy with progress so far. And this thing is sturdy as a horse!

3 thoughts on “(1st Weekend) – Progress on Bobby’s Halloween costume. Seriously, what is this thing!!”

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