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Picture of Star Wars BB-8 Halloween Prop
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This is an Instructable on how to make your own Star Wars BB-8 droid prop. The design is very simple yet convincing and made with only a few main items: an exercise ball, foam half ball, and paper cutouts created using Visio. It was a very nice accessory for my daughter’s Halloween costume. To give it some ‘pop’, I added EL wire which made BB-8 really stand out in the evening.

Parts and Materials Required

· Exercise ball (12” diameter)

· White spray paint

· Styrofoam half ball (7.5” diameter)

· Elmers glue

· Googly eyes (2” & 1” diameter)

· Black paint or marker

· Mini red LED

· CR2032 3V battery

· Orange EL wire and battery pack

· 2AA batteries

· Small pieces of Velcro

· Glue gun

· LEGO stick or similar

Step 1: Creating BB-8's Body

Picture of Creating BB-8's Body
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I wanted to keep the design as simple as possible. A seldom used exercise ball was just the right size for BB-8’s body. I sprayed painted it with 2 coats of white paint and let it dry.

I created BB-8’s signature body panels on my computer using Microsoft Visio and printed them out. It took several trial and error attempts to get the right size on the body. I've attached a pdf of the patterns for people to use.

From there I had to figure out how to attach flat sheets of paper onto a round surface. I tried making extra folds in the paper or wetting the paper to soften and stretch it but neither turned out very well. I finally came up with the idea to cut the pattern into circular strips which minimized the creases. Only the center piece had a few visible creases but they weren't bad at all. I then used Elmer’s glue to attach patterns to the body.

Cool prop. Easy to make and it looks really good.

Jchau57 (author)  DIY Hacks and How Tos10 months ago

Thanks! Yeah all my daughter's classmates were pretty stoked.