This video documents our Daft Punk Helmet build from start to finish. The plastic parts were modeled in SolidWorks and then printed on 3 3D printers. The visor was vacuum formed in my kitchen over a CNC machined mold. We used express PCB to build the circuit boards and are running a PIC 16F on each half of the helmet. All the circuitry is contained in each "light assembly" thanks to the use of surface mount components. Check out http://uiproductions.blogspot.com/2010/08/wrapping-up-helmet.html for build details.
No helmets are for sale.
And a special thanks to Volpin for inspiring us to do this.