As the son of an electrical engineer, it had to light up. It also had to have an oscilloscope and on/off buttons. I used Wunder Under to attach the felt pieces to each other and the costume base. I added cardboard inside the costume in a couple of places to give it some rigidity. And I attached El-wire to light it up. We just happen to find a hat with a circuitry design and LED lights at our favorite box store (starts with a T).
I couldn't leave little brother out, so he got a robot costume too.
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