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nice one Nick beautiful work!

Thanks oota.

The top of the box was cut out of thinline and the angled piece on top was made from styrene and glued together. The whole box was then primed and painted with two coats of Gloss Black. I made provision for a switch to be mounted in the top piece, but there is a short somewhere, so the Led's don't go at the moment. I punched out two small discs of reflective Red tape and placed these over the bulbs until the short can be sorted.
You will also notice that the White switch is higher than the others. I thought it would be different as all the pics I have seen show that they are all the same.

Well. If you want to make the Drive Sprockets, here are some pictures I took of my build. Basically black plastic and thin white plastic laminated to the outer edge, than the teeth were marked out ( I got the spacing so, so ) and then used a chainsaw file to shape them. For the center pieces, I used the body of an old ballpoint pen I had lying around and some round plastic tube. The slots were cut in with three cut-off discs mounted in my Wen mini drill.

These are the first and second pics of the sprocket build that didn't come out above.

Hey Nick, nice detail with the sprockets, I found some technoflex yesterday for the tubing would that be of any help for you?
It's black and very flexible with a nice firm rigid edge to it, rubberised plastic basically.

It looks like you have a photo of it on your work bench, do you have some already?

Thanks badges but I will stick with what I have. It seemed to work the first time and stood up to the test. I used plenty of insulation tape on the ends that go into the helmet, and they held it in place most of the day. The tubing is washing machine hose, which was softer than the first one I got (which didn't take paint very well).

Here are some pictures of the extras that were made to finish off the costume. The Aluminium bits were turned up by my friend Rob Craddock and the Com Pad was made up using laminations of different thicknesses of plastic and cutting bits to size for the finer areas.
The holster was made by first making a cardboard template and then going to an Upholsterer friend and having him show me what to do. First time I have done that, and I am quite happy with what was achieved.
Oh, and I used 'Modellers License" when it came to the colours of the panel buttons on the Com pad.

really nice Nick beautiful work mate I love seeing this project progress!

Thanks oota.