Professional Documents
Culture Documents
Realistic Animatronic Lion Mask With Stereo Night
Realistic Animatronic Lion Mask With Stereo Night
Realistic Animatronic Lion Mask With Stereo Night
Realistic, Animatronic Lion Mask with stereo night vision and amplified
hearing
by Solion on January 7, 2008
Table of Contents
Realistic, Animatronic Lion Mask with stereo night vision and amplified hearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Intro: Realistic, Animatronic Lion Mask with stereo night vision and amplified hearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
http://www.instructables.com/id/Realistic-Animatronic-Lion-Mask-with-stereo-night/
Step 32: The lion mask build . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Related Instructables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
http://www.instructables.com/id/Realistic-Animatronic-Lion-Mask-with-stereo-night/
Author:Solion author's website
Artist/Engineer of my own company , only been doing the art side of my work for 3 years now
Intro: Realistic, Animatronic Lion Mask with stereo night vision and amplified hearing
This is the full step by step on building a realistic lion mask with moving jaw
with stereo night vision/color vision system, and amplified hearing augmentation.
This system was first line prototyped in this mask, Others have been made since then
such as the wolves and bear that can be seen on my site along with all my other work at
To build this system takes both art and technology. the first part of this Instructable will deal with the
tear down and rebuild of the video glasses into stereo units. There is a huge amount of information
on the whole build. If anyone has questions you can email me through my site and I will try and answer when I can.
Last page of this build has videos for your enjoyment, including demo of how my jaw systems work.
So sit back, this is going to be a long one. and I hope you enjoy this build.
http://www.instructables.com/id/Realistic-Animatronic-Lion-Mask-with-stereo-night/
Step 2: Continued teardown of I-theater glasses
Hmmm, My sense is that whoever designed these are a Star Trek fan
The basic premise here is to take 2 of these units to make one stereo vision system.
each eye has its own micro TFT display , that we want to drive separately.
http://www.instructables.com/id/Realistic-Animatronic-Lion-Mask-with-stereo-night/
Step 5: Continued teardown of I-theater glasses
Now to disassemble the second unit, the driver board is glued into the glasses frame so it took a little work to remove it safely. but everything else is simple molex or clip
plugs onto the driver board. the LCD's and optics drop out easily as well
http://www.instructables.com/id/Realistic-Animatronic-Lion-Mask-with-stereo-night/
Step 7: Continued teardown/rebuild of I-theater glasses
Beginning the secondary driver board installed. Sadly this configuration is not going to work since the illumination of the tft panel is driven by the small connector with the
red/black connector. this will not start unless both pezio illumination units are plugged into a single driver board.
http://www.instructables.com/id/Realistic-Animatronic-Lion-Mask-with-stereo-night/
Step 10: Continued teardown/rebuild of I-theater glasses
doing it like this instead of creating a whole new cover allows me to support the lens/tft display assembly like it was originally. But as you see we still need to protect the
sensitive electronics.
Sadly this had to change later due to space Issues, but for now if you wanted to just make a pair of stereo video glasses I will show you whats next.
But due to getting my first vac-u -form machine , you will see how I solved a space issue during the lion head portion of the build.
http://www.instructables.com/id/Realistic-Animatronic-Lion-Mask-with-stereo-night/
Step 12: Continued rebuild of I-theater glasses
Not looking to bad , pretty much done some minor trim work and you have a functioning pair of stereo video glasses
http://www.instructables.com/id/Realistic-Animatronic-Lion-Mask-with-stereo-night/
Step 14: Final test of video system
Yes , thats me. yes I am THAT much of a geek. Playing with the stereo vision, resolving some parallax issues. the cameras are farther apart than my eyes so the stereo
effects are very unique. But now the real fun begins as we build the art around the technology.
http://www.instructables.com/id/Realistic-Animatronic-Lion-Mask-with-stereo-night/
Step 16: The lion mask build
basic Fit is checked and we are ready to begin the design process. This is a wholly new system, never tried before so this rig is going to be a one off prototype for future
systems. the idea is simple. 2 cameras one for each eye of the lion. the video feed fed to the video visor.
This will allow for stereo or binocular vision. Also since the cameras are IR sensitive they will give a low level night vision with IR illuminators.
http://www.instructables.com/id/Realistic-Animatronic-Lion-Mask-with-stereo-night/
Step 18: The lion mask build
Kiss one brand new welding helmet goodbye. well at least the face sheild. An expensive choice but the only one since this has a very nice ratchet system and side bolting
supports to hold the lexan foundation for the mask.
http://www.instructables.com/id/Realistic-Animatronic-Lion-Mask-with-stereo-night/
Step 21: The lion mask build
Trying to make a decision on if I should take off the whole earpeice or just partially. For now we will remove only part of it so it will stay on the face as I make a template
for the lexan foundation.
http://www.instructables.com/id/Realistic-Animatronic-Lion-Mask-with-stereo-night/
Step 24: The lion mask build
As I document the build I sometimes forget to grab the camera. In tis case I have made a template with some thin plastic and made the holes need to allow a pass trough
on the video glasses. this was then transfered to a piece of 1/8in lexan (polycarbonate plastic) this was heat shaped over the wooden table with a torch., be sure to have
a fan and windows open. don't kill yourself
http://www.instructables.com/id/Realistic-Animatronic-Lion-Mask-with-stereo-night/
Step 26: The lion mask build
oth outer edges of the video glasses snapped into the lexan foundation. It took several hours of tweaking and remelting to get the form to where I liked it and supported
the video glasses at the right angle and distance form the eyes.
http://www.instructables.com/id/Realistic-Animatronic-Lion-Mask-with-stereo-night/
Step 29: The lion mask build
Okay now onto the nest stage, final fit of the foundation and video glasses.
The video glasses are meant to be removable so the mask can be worn without them. (more on that later)
http://www.instructables.com/id/Realistic-Animatronic-Lion-Mask-with-stereo-night/
Step 31: The lion mask build
kay looks like everything is finnaly in place. time to button it up and make our spacers between the foundation and the headband.
I vouch for E6000 only because I used it to hold my electronics in my battle bot. When everything else let loose. The stuff held by E6000 stayed in place.
http://www.instructables.com/id/Realistic-Animatronic-Lion-Mask-with-stereo-night/
Step 34: The lion mask build
Okay , time for the next step. everythign is locked in place, Now to begin actually buidling the lion portion of this build.
http://www.instructables.com/id/Realistic-Animatronic-Lion-Mask-with-stereo-night/
Step 36: The lion mask build
Here is the nose/forehead foundation piece we build everything outward from. Wedded tot he center support with hot glue and E6000 we begin he process of setting the
upper jaw into place. this will help me align and map out the rest of the construction
http://www.instructables.com/id/Realistic-Animatronic-Lion-Mask-with-stereo-night/
Step 39: The lion mask build
Now we can begin trimming the forhead/nose peice and adding material on the end of thenose as well.
http://www.instructables.com/id/Realistic-Animatronic-Lion-Mask-with-stereo-night/
Step 41: The lion mask build
Next we trace the outline of the lower jaw and remove materal to the depth of 1/4 inch to recess the lower jaw into the foam
http://www.instructables.com/id/Realistic-Animatronic-Lion-Mask-with-stereo-night/
Step 44: The lion mask build
We now get to carving and shaping the foam for the forhead.the muzzle portion will mostly e defined by the aluminum mesh. As you can see we have added a peice to
the very forward part of the upper jaw.
http://www.instructables.com/id/Realistic-Animatronic-Lion-Mask-with-stereo-night/
Step 47: The lion mask build
Another picture, Not looking too lion like yet, but its getting there.
http://www.instructables.com/id/Realistic-Animatronic-Lion-Mask-with-stereo-night/
Step 49: The lion mask build
Now I build up the forhead and start the eyebrow arch formthe nose. Keeping in mind I need to make sure i leave enough room for the cameras on order. Had some nice
color units. But decided to spend the extra money for the more expensive nightvision/color units that will not only support good color, but IR sensitivty that will allow for
practical night vision. Also the optic on the units bought are interchangeable to wider fields of view.
http://www.instructables.com/id/Realistic-Animatronic-Lion-Mask-with-stereo-night/
Step 52: The lion mask build
start working finer details of the upper jaw and cheeks into the design, upper brow and forehead pieces go on, waiting for shaping on those when I get the camera mounts
installed
http://www.instructables.com/id/Realistic-Animatronic-Lion-Mask-with-stereo-night/
Step 54: The lion mask build
continued shaping of the muzzle. I work from photos an all my work , so it is a painstaking time to make sure to remove all forms and angles that are not lion like
http://www.instructables.com/id/Realistic-Animatronic-Lion-Mask-with-stereo-night/
Step 55: The lion mask build
now to move to the electronics side of things again. we need to know how much room we need for the camera eyes
I found better cameras to do both the color and IR vision, Sadly they came with a ring of IR leds hat were not going to work for our application since the camera optics
were going to be surrounded by plastic eyes.Since these allready came with IR LEDS it seemed a good idea to remove them and recycle them into the IR illuminator for
the nose.
http://www.instructables.com/id/Realistic-Animatronic-Lion-Mask-with-stereo-night/
Step 56: The lion mask build
Whats this?, well with the new cameras they were just not going to fit in the same space as the much smaller ones I originally bought for this build. So the front cover was
going to have to come off.
This means we need to create a new smaller cover for the sensitive electronics. Enter the vacuform machine and the left over second video assembly to make my piece.
Ebay saves the day as this machine is only 350.00 plush shipping , a must have for any crafter .
http://www.instructables.com/id/Realistic-Animatronic-Lion-Mask-with-stereo-night/
Step 59: The lion mask build
Here it is married to the video glasses, it reduced the space it took up severely. Had I thought about it I might have used some clear vaccuform plastic
http://www.instructables.com/id/Realistic-Animatronic-Lion-Mask-with-stereo-night/
Step 61: The lion mask build
Okay , with some 1/2 aluminum l brackets make by hand we mount and align our cameras. Hmm "Q" looks impressed
Now you may notice that the angles of the face are exaggerated some. well celluclay when it dries , shrinks. also it leaves me enough material to sand and do final
shaping before laying down the fur.
http://www.instructables.com/id/Realistic-Animatronic-Lion-Mask-with-stereo-night/
Step 64: The lion mask build
These are second phase photos of adding features to the face. Often I have to take it to near cracature of a face due to the fact that the fur will soften and fill areas of the
mask.
http://www.instructables.com/id/Realistic-Animatronic-Lion-Mask-with-stereo-night/
Step 66: The lion mask build
Next I define dead center of the mask and decide where my glue line is going to be. Since he will have a full mane I need to make sure that I dont glue down any fur past
that point since I will need a place to lay down the mane.
http://www.instructables.com/id/Realistic-Animatronic-Lion-Mask-with-stereo-night/
Step 69: The lion mask build
stretching the fur as I go I work down both sides of the face., very time consuming but you get a nice effect with it as it prevents creases
http://www.instructables.com/id/Realistic-Animatronic-Lion-Mask-with-stereo-night/
Step 71: The lion mask build
so I take the LEDs and mount them into the nose in parallel 3v lights them up nicely and I simply pigtail a wire from the back of the nose and mount it into the head . but
first a test to make sure they all light
http://www.instructables.com/id/Realistic-Animatronic-Lion-Mask-with-stereo-night/
Step 74: The lion mask build
now we break out the airbrush and do a little trim work around the muzzle and upper lip. Time to mount the lower jaw
http://www.instructables.com/id/Realistic-Animatronic-Lion-Mask-with-stereo-night/
Step 76: The lion mask build
Removed section of plastic from the back of the jaw since it was not fitting correctly
http://www.instructables.com/id/Realistic-Animatronic-Lion-Mask-with-stereo-night/
Step 79: The lion mask build
Checking the lower jaw fit with the mouth closed
http://www.instructables.com/id/Realistic-Animatronic-Lion-Mask-with-stereo-night/
Step 82: The lion mask build
And time for toung! Silicone rubber toung with texture, It is held in place with E6000.
http://www.instructables.com/id/Realistic-Animatronic-Lion-Mask-with-stereo-night/
Step 84: The lion mask build
Now we begin to fur the ears, Hot glue and greative trimming witll give us the look we want
http://www.instructables.com/id/Realistic-Animatronic-Lion-Mask-with-stereo-night/
Step 86: The lion mask build
Tufts added to the interior folds of the ears.
http://www.instructables.com/id/Realistic-Animatronic-Lion-Mask-with-stereo-night/
Step 89: The lion mask build
continued trimming and brushing around the muzzle. some glue based flocking and hand punch of fur
http://www.instructables.com/id/Realistic-Animatronic-Lion-Mask-with-stereo-night/
Step 92: The lion mask build
Removed the eletret microphone element and have now pigtailed from the original solder points a foot long wire to the microphone. this is a really tiny board so you have
to be careful
http://www.instructables.com/id/Realistic-Animatronic-Lion-Mask-with-stereo-night/
Step 94: The lion mask build
Next we add solder wires to the tbs where the original earpiece was connected. again about a foot long.
http://www.instructables.com/id/Realistic-Animatronic-Lion-Mask-with-stereo-night/
Step 97: The lion mask build
Microphines added and we tuck the wiring away. we will come back to this when it is time to pad the interior of the mask and do final detail work
http://www.instructables.com/id/Realistic-Animatronic-Lion-Mask-with-stereo-night/
Step 100: The lion mask build
a little trim work and we begin to see the mane take shape, but no bones about it. we are not nearly done
http://www.instructables.com/id/Realistic-Animatronic-Lion-Mask-with-stereo-night/
Step 103: The lion mask build
We open the eyes abit more and do the detail paint around them , then fit the plastic lenses around the camera optics again,then work on finer details above and around
the eyes
http://www.instructables.com/id/Realistic-Animatronic-Lion-Mask-with-stereo-night/
Step 105: The lion mask build
now the top of the head with Prismacolor dyes
http://www.instructables.com/id/Realistic-Animatronic-Lion-Mask-with-stereo-night/
Step 107: The lion mask build
Now the Audio and video cables are created for th system , with video outs and ins. YES you can watch your IPOD inside the mask
http://www.instructables.com/id/Realistic-Animatronic-Lion-Mask-with-stereo-night/
Step 110: The lion mask build
Here is one of the battery packs to drive the cameras , I used 1/2 in audio jacks for this. all the connectors were either different sizes or different types to prevent a
connection mishap
http://www.instructables.com/id/Realistic-Animatronic-Lion-Mask-with-stereo-night/
Step 112: The lion mask build
Here are the supports in place on the inside of the mask
http://www.instructables.com/id/Realistic-Animatronic-Lion-Mask-with-stereo-night/
Step 114: Cable ties
Now it is just a matter of tying cables into place , split loom tubing and clips to the back of the head, then to the pocket made for the electronics.
http://www.instructables.com/id/Realistic-Animatronic-Lion-Mask-with-stereo-night/
Step 116: Electronics pocket
Everything fits in a custom pocket made for the batteries and electronics. this would be on the inside of the lion suit with the mane over the back.
I hope you enjoyed this trip through this madness. Included here are some videos of how the systems work (as documented for a wolf with the same system) pelase feel
free to peruse my site and other videos of my work .
I have only been doing my art for 3 years now and I hope to continue creating these pieces. Perhaps one day you will see my stuff in the movies. who knows.
http://www.instructables.com/id/Realistic-Animatronic-Lion-Mask-with-stereo-night/
http://www.instructables.com/id/Realistic-Animatronic-Lion-Mask-with-stereo-night/
Related Instructables
Comments
50 comments Add Comment view all 117 comments
have you thought about using old camcorder digital viewfinders? there more like £30 for the pair rather than £400
also you should add more leds to take advantage of the ir camera i think,
Dan
http://www.instructables.com/id/Realistic-Animatronic-Lion-Mask-with-stereo-night/
bornkilr says: Oct 16, 2010. 9:07 PM REPLY
What kind of fur is that? And where can you get it?
http://www.instructables.com/id/Realistic-Animatronic-Lion-Mask-with-stereo-night/
simpsoni says: Oct 19, 2009. 6:42 AM REPLY
very many steps,but thank you this is amazing mask
http://www.instructables.com/id/Realistic-Animatronic-Lion-Mask-with-stereo-night/
ReCreate says: Jun 19, 2009. 11:27 AM REPLY
wow, i bet you set a record.
http://www.instructables.com/id/Realistic-Animatronic-Lion-Mask-with-stereo-night/
Jakub says: Jun 29, 2008. 8:02 PM REPLY
WOW I like the way you make masks especially the lion.............. so realistic, did you go to school to learn this... amazing
http://www.instructables.com/id/Realistic-Animatronic-Lion-Mask-with-stereo-night/