This will make installing the mesh much easier once it is covered with fabric. Next, spray paint both sides of the mesh black. This will make the mesh disappear behind the fabric you will use to cover the mouth and because it won't interfere with your eyes from the inside, it will greatly increase your ability to see out of the Mau5head.
A white or silver mesh will be very difficult to see out of and will make you very dizzy - do yourself a favor, spray it black!
Do not attach mouth yet, this will be the last step in creating your Mau5head. Start by laying your fabric face down on the table and then placing the ear on top of it. Pin around the perimeter of the ear with fabric pins while gently stretching the fabric so it fits nice and tight against the foam. Continue this around the entire perimeter of the ear. When the glue has cooled, trim off the excess fabric very closely to the foam and repeat process on other ear.
Pin the stitch witchery in a few places to hold until the fabric is stretched over it. Now, very carefully go around the perimeter of your ear stretching the fabric up the edge and over the back, and pin the fabric at the back of the ear. You are doing this to give a tight fit up against the stitch witchery, but not pin exactly to it. Move slowly around the edge, allowing 10 seconds or so over each area to fully adhere the fusible web. Let the fabric cool completely, and then trim the edges.
This will be your finished edge, so give a little teeny bit of stretch to the fabric as you trim it to get the smoothest even cut along the edge. Secure the edges bottom near the rod ends with hot glue, making sure they are very smooth — this edge rests against your head and an even surface is very important! In this step, be extremely patient!
Some fabrics are somewhat see-through, so before you put the fabric on, remove all sharpie markings with rubbing alcohol. Place it on the globe in several areas and stretch it to get an idea how it will mold to the area you are about to cover.
Use your C-clamps to hold the fabric in place after folding over the bottom lip, and stretch the fabric up and around, securing with clips or pins as you go. If you have a friend who sews, bribe them with free pizza and ask for help. Remember that the glue can seep through many fabrics, so test on an inconspicuous area first. After the fabric has been stretched into place, you can secure with hot glue, or with stitch witchery if you will be overlapping fabric to fabric stitch witchery between fabric layers and steamed to adhere.
On the inside of the lips, use hot glue on the back side of the foam — not on the lip itself! You want the fabric taut over the foam lip edge and secured only on the back where the metal mesh will touch.
Repeat this process on the top half of the head, and at your seam you can either trim smooth or roll under for a finished seam like a sewn edge would look. Secure with hot glue or, my preference, steam edges together with stitch witchery. Secure fabric on inside of neck with hot glue after rolling fabric over cut edge of neck opening. Cut small slits with a razor blade through holes for ear rods and any holes cut for eye lighting.
Now that your head is completely covered with fabric, reattach ears. This will help make sure the eyes get positioned properly. Go ahead and put in whatever lighting source you have chosen. If possible, try to put a reflective material such as foil as a background in the entire eye area to intensify the light output from the eyes. Secure the power source to the inside of the head with self adhesive Velcro strips.
Test fit your eye domes over the lighting and inspect for placement. When you are satisfied with placement, run a thin bead of hot glue around inner edge of the white acrylic dome, one at a time, and place over lighting source.
Be careful to not drip any glue on the fabric of the head. Finally, the last piece of the puzzle is ready to go in! Cover the metal mesh mouthpiece with either a piece of nylon tights material, or sheer chiffon fabric and secure edges with either hot glue or tape. Place the mesh inside the head, holding edges tight against inner edge of lips. You will be securing the metal mesh in place with screws so that you can replace fabric if needed, or make other adjustments without having to battle a hot glue mess later down the road.
When you have decided where you would like the screws to attach, pierce through the tape edge of the mesh to cut through the tape and fabric, and to start a path for the screw to go through into the foam lip edge. Screw through this slit into the foam, and repeat in several places around the mouth edge.
Check from the front from time to time, and see where the mouth needs to be screwed in, giving the proper shape to the mesh. Switch on the lights and put on that amazing Mau5head you just created, and rock it like you mean it! You deserve it ;D. Participated in the Halloween Epic Costumes Challenge. Reply 5 years ago. I used the dremmel to go back around the mouth and make small adjustments making sure to be careful. As far as the eyes go, I layed a piece of grit sandpaper on the ground and sanded away the rough edges.
Reply 9 years ago on Introduction. Great comment man, thank you! I really appreciate and respect the collaboration of everyone on this instructable's comment thread.
Really great work and thanks for the explanation on the fabric. I have read all of the comments a ton of times, and I am at the final stage of getting the fabric on the head. I have spent hours trying different techniques but have taken the plunge of cutting of debulking the fabric.
So it seems you have a seam at the bottom-back of the head? I am considering using your technique, so any more suggestions would be greatly appreciated. My suggestion: 1. Lay one piece of tape horizontally across the entire back of the globe and stretch either the top or bottom piece of fabric to it.
Smooth it out and glue it permanently behind the lip in the mouth. Trim the fabric tight to the tape. No need to leave any overhanging. No need to be overly neat here because we will cover the seam see step 6 below 4. Then lay another piece of tape directly adjacent to the first and do the other half.
Trim this piece tight to the tape, too. Cutting stretchy fabric with scissors sucks--I didn't have a clean seam, so I made a "cover up" piece. In my pics below, the first one is the ugly seam I orig made. The second pic show what my cover-up piece did to hide it. Mine is even more bumpy because of my first attempt to make the seam without the cover-up. If I would have planned on using the cover-up in the first place it would have been smoother.
The flash on my camera coupled with the sheen of the material seems to over-emphasize the bumps, too. In hindsight this approach would have worked well for the ears, too. This is exactly what I was looking for and am sure it will help many others as well. My wife has one of those cutting wheels, so I will definitely use it to cut the 'cover up'.
One more quick question - does the cover up piece go all the way around to the corners of the mouth? Thanks again for the great info. Yeah, mine goes all the way around. Looks kind of like an extension of the top lip if you view the head from the side.
It would be nice to have no seams, but that seemed impossible. Thankfully you can't see the seam from the front. I hear ya on the impossible - just dont see it.
I cant even begin to see the seam on the front of the head in your pics, so thats great. Looking forward to going with this method tonight and finally finishing up. Thanks again for all of the great tips. Many of the helmets that we see in this episode have been worn by Joel and each has been hand crafted to meet his specifications. As he points on in the video, with such a unique project sometimes human error occurs which can be dangerous, like when they accidentally sent too much power to the mau5 head during a soundcheck.
Watch the video below to get a better idea of what goes into creating these mau5 heads, along with more information on the special project in collaboration with NVDIA. Watch episode 1 of The deadmau5 Project. Music Review. Hip Hop. A tech geek at heart, Zimmerman hasn't hesitated to switch things up with the performance prop, and that experimental spirit has yielded quite a number of mau5head variations over his career thus far.
Read on for a look back at some of the most memorable mau5heads thoughout Zimmerman's career. Before we get into the various forms of the mau5head, it's worth pointing out its original form. The Canadian producer first performed with the head during a set in Nova Scotia in An inner plastic framework covered with fabric and a see-through mesh mouth was all it took. While Zimmerman doesn't typically dress in suits for shows these days as pictured above, the mau5head has only evolved to become more fanciful in the functional advancements and designs made since.
On the opposite end of the spectrum, the LED mau5head is almost undoubtedly the most advanced form of the helmet - though it has had numerous different versions and tweaks.
The LED mau5head first appeared in and quickly became a central part of the show. Fans know what a good light show does to augment a production, and Zimmerman seized the opportunity to make the mau5head itself part of the light show. Central to Zimmerman's sight was a small camera that would project an image to him from the outside. Evidently, the first version of the LED mau5head demanded a lot from a performance standpoint. It was heavy, heated the inside of the helmet, and made visibility of the outside particularly difficult.
The iconic cheese-themed mau5head came about from a contest won by Lance Thackeray. The simple yet clever entry to the "Design The Next Mau5head" competition won Zimmerman's praise and landed Thackeray the chance to meet him in Thackeray's design won out of nearly 2, submissions to the contest.
Zimmerman went on to render Thackeray's 2D design into a 3D reality with the help of his engineering team before going on to wear the cheese-themed helmet on the Meowingtons Hax Tour that year. This version of the head was featured on the album's cover art.
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