Onath stay with foam to make the puppet and use the material to cover it.  You will see the seem when you sew the material but you could use the seam like a metal seem by drawing rivets on each side like a real metal being put together.  I think if you keep the robot fairly squarish (if such a word?) then you could keep the seems to the back if you don't want any seems to show in the front.

I would be worried about cardboard wearing quickly with sweat ect.....

Daryl H

Good idea Daryl... you could even put gromets or silver buttons as the rivets that would hold steel together.

Billy d.

A material like lycra would be a good choice.  Several months ago there was a Tin Man puppet posted that was covered with lycra and it look great.

If the material is shiney and the lines are straight you should be able to make a convincing robot.

I did a little checking into working with LEDs and didn't find much info on wiring them.  But here are a few options:  You can find LED christmas lights that you could install in a puppet from the inside with only the light showing on the outside.  If I only wanted a few lights I'd even cannibalize a cheep battery opperated LED flashlight.  Then you have all the fittings you need, you know what king of batteries you need and it all in a portable package.  Now I'm saying this and I have some ability when it comes to electricity so I'd just kind of muddle my way through.  If this isn't your area you may need more specific technical advice.

I'm not sure how much light source you want but I did find this interesting " Led Throwies "

http://graffitiresearchlab.com/?page_id=6

Instructions on how to make your own

http://www.instructables.com/id/LED-Throwies/

Material list and where to buy

http://www.instructables.com/id/EWL9H74LX4EP286JFD/

I'll keep searching for the small mini light sets used on minature christmas trees.

Billy D.

They don't seem to bad I think I just need to find a switch and a way to house the 3v battery.

Covering your puppet in a fabric like Lycra that has a shiny surface is a great idea but if you want to try something else that is similar to Sculpt n Coat you could use spray on Tool Dip. You find it in hardware stores. The puppet you see to the left was made this way.  His head is actually paper mache' covered in the spray on Tool Dip but his body is made of foam and then covered in it. I used green for him but there is a clear version you could use after you painted the foam silver that would give you the glossy look of metal.

I love the idea of the cardboard helmet!  So glad you found that and shared the link.  It would be prefect for making hats or props for puppets that where light weight. Actually if you covered both the inside and outside with a layer of Tool Dip or even Sculpt n Coat I think it would hold up even as a puppet head.  

I'll keep searching for the small mini light sets used on minature christmas trees.

www.consumercrafts.com has several types of light sets. various colors too.


Also, you could try the light accessory sets that they sell at auto parts stores. They come with a battery pack for "try me" purposes in the store. I have used the entire set up for lights a space ship before and it looks and works great. The LED lights have lenses over them, come in a few colors... but are pricey at about $16 with tax.

I like the cardboard helmet idea too.  Great pattern!  You could always substitute the cardboard for thin plastic if wear is a concern.

Hey Billy: Those throwies look like so much fun!  If we all lived in the same city, I'd say let's have a throwie party!  We'd make them while having snacks and then go downtown and decorate something with them.