Here’s a costume I started in 2006 and finally finished in 2008. I’ve worn it on two Halloween nights and the response has been awesome – for which I am very grateful! The kids just love it because the carousel lights up and rotates, plus the hammer hands are really long and huge…I’m like a circus!
Here’s some info about the construction:
* There are 225 individually wired LED lights.
* There are at least 600 hand-soldered points in the wiring.
* The entire suit was painted by hand.
* The carousel headpiece is made out of foam-core board, paper, adhesive and paint.
* The hammers and arms weigh 4 lbs each.
* The headpiece weighs 4.75 lbs.
* The hammers are constructed using a foam frame, and then wrapped around with paper. A long aluminum rod is inside the arms, supporting the hammers.
* The lights and motor are powered by a battery pack worn on the lower back. The battery pack weighs 9.5 lbs.
* In order for the top of the carousel to rotate while maintaining power to the LEDs in the top section, there is a custom made ‘track’ of copper sheeting that is always in contact with multiple wire brushes, so power is constantly supplied to the lights above as it rotates.
* The entire outfit took more than 200 hours to make — spread out over a couple of years. It began as a basic costume, then evolved into a more elaborate project.
I hope you enjoy it – sure was fun to make!