Category Archives: Costumes

Quick project: 24-hour Cosplay Sword

Cosplay Sword 1

Junior Evil Mad Scientist Chris came to us for help with what turned out to be a funny little (well, huge) cosplay prop project. The kind of project that starts off with a conversation that goes like this:

“You want to build what?”
“A giant sword for my costume for FanimeCon!”
“And when do you need it by?”
“Uh… tomorrow?”

So, we got to help make a 64″ long replica sword, one of several from the flash game Epic Battle Fantasy 3 (which we had admittedly never heard of before), in what turned out to be kind of an interesting (if quick) project.

Chris drew up the outline for the sword in Inkscape, by tracing the outline of a bitmap drawing of the sword in a larger collection (where you can find this one in the top row, one third of the way from the left).   We cut the outline on our CNC router from lightweight 3/4″ hardwood plywood— strong enough to not be floppy, yet light enough to be carried — and sanded the sides until it could be handled without creating splinters. We also sanded a slight bevel around the edges of the blade, so as to create the illusion of a sharpened edge without actually thinning it much around the edges.

Next, we needed to paint the sword silver.  We had some silver spray paint on hand (left over from our 555 Footstool project!), but if you directly spray paint lightweight plywood, it tends to soak into the wood unevenly, dry slowly, and leave a finish that awkwardly highlights the grain of the underlying wood.  Instead, we coated the sword with a fast-drying sanding sealer and allowed it to dry for two hours before getting out the spray paint.


Cosplay Sword 3

In the mean time, we made the hilt details— what might count as greebles —by laser cutting two sheets of thin 1/8″ thick plywood on each side, in a shape slightly inset from the outline of the thicker plywood.  There are two of these, one to go on each side of the hilt.

Cosplay Sword 2

Once the sanding sealer had dried enough to gently sand, we test-fit the parts together. The photo above shows how the parts look after laser cutting and with the slick, yellowish finish that the sanding sealer gives to the plywood.

Next, we spray painted the body of the sword. Primer gray for the hilt section and metallic silver for the blade section, and allowed it to dry overnight.

Separately, we painted the laser-cut overlays black with black one-part polyurethane finish (the same type that we used for our ASCII art Tie Fighter project), and allowed them to dry separately.

Cosplay Sword 4

In the morning, a little superglue attaches the newly-black hilt details, an old leather belt becomes some lashing details, with the help of a staple gun, and… it’s off to the show.

In case you’re interested, you can download a copy of Chris’s sword design here, as an Inkscape SVG file.

You can find more costume projects in our Halloween Project Archive.

Classic Robot Costume

Our friend Ben sent us this picture of his son’s “robot” costume:

…lit with, what else, EMSL surplus traffic light— kill your eyes —LEDs. It’s five series pairs of your LEDs pointed up inside the costume and down the sleeves so the light bounces around and positively pours out of every crevice – highly visible for trick-or-treating!  There’s another two pairs, not lit in the picture, controlled by the momentary switches on the front panel for “turn signals.”

Thank you, Ben for sharing your project! And we still have just a few more of those eye-killing LEDs in the shop.

Evil Mad Scientist Halloween Projects

EMSL Halloween Roundup

Halloween, one of our favorite holidays, is fast approaching. We’ve updated our Halloween Projects Archive once again to ensure that all of our Halloween projects are gathered together in one convenient location. If one of our projects inspires you to make something, we’d love to see the results in the flickr auxiliary.

Halloween Projects from Evil Mad Scientist Laboratories

The Great Evil Mad Scientist Laboratories Halloween Project Archive!

Halloween is one of our favorite holidays, and our collection of Halloween projects continues to grow. Every fall we update it to include our latest projects for the season. In the list that follows, we’ve organized dozens of our Halloween projects into categories: costumes, pumpkins, decor and food.

Last updated: 10/2015.

Continue reading Halloween Projects from Evil Mad Scientist Laboratories

A new Kraftwerk-inspired LED tie kit?

LED Tie - 28.jpg

Well, almost— With a breath of new firmware, our Larson Scanner kit takes us on a trip to the late 1970’s.

In the old videos of electronic music pioneers Kraftwerk performing their classic The Robots, a prominent prop is the animated LED necktie worn by each member of the band. If you haven’t seen this, or it’s been a while, you can see it right here at YouTube. (Additional viewing, if you’re so inclined: Die Roboter, the German version.)

The Kraftwerk tie has nine red LEDs in a vertical row, and one lights up after the one above it in a simple descending pattern. And what does it say to the world? One thing only, loud and clear: “We are the robots.” Now, if you’re anything like us, the most important question going through your head at this point is something along the lines of “why am I not wearing a tie like that right now?


The good news is that it’s actually easy to make one. And the starting point? A circuit with nine red LEDs and just the right spacing: our open-source Larson Scanner kit. With minor modifications– a software change and dumping the heavy 2xAA battery pack–it makes a pretty awesome tie. In what follows, we’ll show you how to build your own, complete with video.

Continue reading A new Kraftwerk-inspired LED tie kit?

Evil Mad Scientist Laboratories: Year 3

Evil Meggies

Happy birthday to us! Evil Mad Scientist Laboratories is now three years old.

To celebrate, we’re rounding up our most interesting projects from this past year.

Quick projects and observations:

Magnet tricks
17 cool magnet tricks

The monetary density of things

Cheap calendar 2
Cheap Perpetual Calendar

Parts Tray-14
Contact Lens Case Small Parts Tray

Simple LED Projects:

lanterns - 11
Quick, easy, temporary, and beautiful LED garden lights

RoboGames Awards (on)
RoboGames Awards

LED Ghostie
LED Ghosties for Halloween

Food Hacking:

Dry Ice Martini
The Hungry Scientist Handbook

Decoder 2
South Indian Restaurant Menu Decoder


"That's no melon!"
“That’s no melon!”

Grillin 2
Hot Dog Bun Grilling Jig

LOLHearts - 34
Improved Custom Message Hearts

Apple Pie
Now that’s an Apple Pie!

Caprese - 16
Eyeball Caprese

Fractal Snowflake Cupcakes - 24
Fractal Snowflake Cupcakes



The CandyFab 6000


Harley Sleeps
Cardboard Cat Chaise

EdgeLitCard - 49
Edge-Lit Holiday Cards

Hex Boxes5
Hexagonal Stacking Boxes

frabjous - 01
Making a Frabjous

Electronics Projects

Interactive LED Dining table
Interactive LED Dining Table Circuit


Color distortion
Giant seven segment displays

DarkPumpkin - 11
Dark detecting jack-o’-lantern

SolarCircuits - 06
Simple Solar Circuits

Soft Circuit Merit Badge14
Soft Circuit Merit Badge

Kit Projects

Meggy Rainbow
Meggy Jr RGB

VideoPeggy - 09
Video Peggy in action

Peggy 2 RGB
Peggy 2 RGB

2313Card - 1
ATtiny2313 breakout boards

Revised ATmegaXX8 boards

Crafty Projects

d12 Bag
DIY d12 Handbag (of Holding)

Meggy Jr RGB Cozy-21
Meggy Cozy

no-sew iPhone cozy14
No-sew iPhone Cozy

fabric klein bottle
Fabric Klein Bottle

Seat recovery
Reupholstery with Used Denim

Missile Command Skirt 24
Missile Command Circle Skirt

Fishbowl cat quilt29
Fishbowl Cat Quilt

Turning Mollie into Maulie

Bicycle lunch bag
Bicycle Frame Lunch Bag

Acrylic Nesting Bracelets-1
Sinusoidal Bracelet Design

Microcontroller Projects

Time exposure
Tennis for Two, a video game from 1958

stockpumpkin - 11
Scariest Jack-o’-Lantern of 2008

mignonette - 09
70 bits of gaming goodness

Serial Port Added
AVR Serial Communication

lissajous-dark - 07
POV Lissajous figures

Mobius Circuit - 21
Single sided circuit board

A Bulbdial Clock

Geek Design

Snowflake generator
Vector Snowflake Application

The Amazon Kindling

Pi (squared) trivet - 9
Pi Pie Trivet

lego - 2
Lego Kitchen Crafts

Binary Birthday
Binary Birthday


20 millicenturies of Evil Mad Scientist Laboratories


Happy birthday to us! Evil Mad Scientist Laboratories is now two years of age. Collected below is a “Best of Evil Mad Scientist” for the past year: Some of our favorite projects that we’ve published over the last twelve months. Here’s to the next year!

Quick projects:

Set of bands
Rubberbands made from old bicycle innertubes.

vertical light tent setup
Light tent made from a lampshade.

Still life with yellow paper (group shot 2)
Chip bugs


Spool spinner from an old fan.

Quick C to D adapter
The $1.00 C to D adapter

Electronics projects

Weekend Projects Podcast!
How to make a Joule Thief from Make: Weekend Projects.

lights off?
How to make a dark-detecting LED night light.

The Great Internet Migratory Box Of Electronics Junk
The Great Internet Migratory Box of Electronic Junk

Finished 1
How to make a Sawed-off USB Key

AVR microcontroller projects

Using an ADXL330 accelerometer with an AVR microcontroller

Snapper - 09

Kit Projects

AVR Target Boards

Four Panels 2
Interactive Table Kits

Resist1- Wall hanging

Peggy v 2.0

Crafty Projects

Q*bert close-up

vintage software book handbag
Software Handbag

iPod inside
iPod cozy

Earrings 2
Fimo Fractals

Miniature Art Car
Mini Art Cars

New wing
Umbrella Bat Costume v 2.0

Food Hacking

Cooking hotdogs

555 LED flasher 1
Circuitry Snacks

Googly FSM
Edible Googly Eyes

Sierpinski Cookies-11
Fractal Cookies


Sugar Chain
Printing complex shapes: Sugar Chain

Before and after 2
Candyfab improvements: higher resolution and edible output


Usage 3: First operand
Rotary Fraction Adding Machine

toner - 15
Electric Origami

Observations & silly projects:

Cat volume computation
Volume of a cat

Pacman Halloween

Lego Projects:

Lego Shooter
Forbidden Lego review & build

Technic Bits
Efficient Lego Storage


suction tool
Obscure electronics tools

Lee Valley & Veritas catalog
Lee Valley & Veritas Catalog Review


Twisted leads (close-up)
LED Stoplight

All the parts
hp2600n - 178
HP Color LaserJet 2600n