The following Instructable occurred during 7am and 9am on October 31, 2010. After seeing comments posted by D00M99, falafel, and Kryptonite on my Grunt costume. And conferring with the elated kid in the Grunt costume, I learned what a Needler was. I knew I could whip one out, just needed to sleep on it. So this morning I did a run to Wally world and started work on a Needler for the Grunt costume. It’s done, consider it a Halloween treat for the aforementioned individuals. Enjoy!

Step 1: Materials

Youth Shin Guards
3 Foam sheets in orange – 8.5 x 11
Cone shaped floral foam
Black markers – thick and thin
Black Acrylic Paint
Disposable 10 inch plate
Dowel or Small paint roller
2- 3 inch screws or bolt
Drill or Screwdriver
Paper towel
Scissors
Duct tape
Sandpaper
Toothpicks or Skewers
Pink glow bracelets - 12 total or neon pink paint
Needle and thread (Maybe needed)

Step 2: Preparing the Front of the Needler

Take shin guards and sand off any logos. Tape straps to back of guards (in case you ever want to use them). Use marker to create details. Make hole an inch from the top of the guards. Use black paint and a wet paper towel to give a war beaten look, let dry.

Center of Front

Cut sides of plastic plate and trim edge. Cover in duct tape. Detail with marker and cut 1 ½ hole an inch from center back, then use black paint and a wet paper towel to give a war beaten look, let dry.

Paint the paint roller black, let dry. Put plate through the paint roller. Set aside, this will be used for final assembly.

Step 3: Preparing the Back of the Needler

Draw the pattern above on two 8.5 x 11 sheets of orange foam with a thin maker. Draw over with thick marker to create detail. Cut sides to taper to front of Needler . Use black paint and a wet paper towel on the areas that need to be gray, let dry. To give a war beaten look, use black paint and a wet paper towel, let dry. Duct tape to front pieces, making sure the foam goes over the screw hole.

Placing the floral foam and covers

Cut the cone to fit the top back of the Needler, duct tape into place making sure that the dots on the orange foam are over the floral foam. Place the toothpicks in the marked holes, this will secure it and create pilot holes for glow bracelets or painted neon skewers.

Covers
Fold last sheet of orange foam and cut to look like picture. Use black paint and a wet paper towel to give a war beaten look, let dry. Use duct tape to put in place.

Step 4: Putting It Together

Screw top and bottom of Needler on to prepped paint roller. Use needle and thread to tighten front down and create angle, if needed.

Step 5: Finishing Touch

Needles
Activate bracelets and place on gun replacing existing toothpicks.

Variation
Paint bamboo skewers with pink neon paint and place on gun replacing existing toothpicks.

Enjoy!!