Category Archives: #Horror

Bobby’s Silent Hill: Pyramid Head Costume 2015 – Week 2 Progress


So I’ve almost completed the head part of this costume. And since I’ll be attending the Vancouver Halloween Parade, I have to make sure not to put any gore and blood on it as its a “family” oriented event. But don’t worry, The gore will be added after this.

Since last week, I’ve added mesh & cast iron pipes & foam.

I started trying to screw in the mesh with fasteners and washers … but it was actually way stronger and faster to just hot glue it.

The foam was glued in using my favorite glue: PL 8x I haven’t yet found something this glue can’t do! It’s low odor and does not melt foam (most glues do this because of the acetone).

With these major upgrades the head already looks badass!

Drinking always gets those creative juices flow!

Adding some of these Cast iron union joints (these are my favorite parts, they just feel really good in the hands).

And since the structure is build with 1/2″ plywood, attaching anything is simple.

Adding the foam strategically to fit your body is key!

Now that you have the whole thing built up. Adding some paint just makes the whole thing POP!

After a little bit of searching. I found that the best color and style for this is the Hammered Brown. It gives it a cast iron sheen and gives it a galvanized texture. Perfect for this project!

The mandatory painters tape!

And after a few complaints from the smell coming from the wife … and voila. Let it dry overnight and you have yourself a metallic looking helmet!

Now to make the rear wiglet looking things. Note, that I could have left these out as they are pure aesthetic … but no. I go all the way!

And since I only want it to look like the bolts actually bolt right into my spine … I’ll end up cutting these.

Ya, I love sparks! I know.

Using the PL glue again, you can add to this piece.

And that’s what it’s supposed to look like once installed. And, to give it some extra emphasis … I’ll actually keep these metallic silver (galvanized).

And don’t forget to paint the interior foam black … makes it look professional.

Up next: Don’t forget the most important part:

I figured that there was no other way to make this perfectly other than 3d printing … So I got this commissioned: MakeFamilyFun’s Hub kindly made this part for me after I designed on it Solidworks. For about $35, I was able to get this part printing withing a few hours.

Up next, install the red gear, buy material for the bottom of the costume (the pants), and make the ginormous sword … standby!

(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!