I agree with your analysis. Not only did the project look like fun to build, the creator seemed very bright and charming. I enjoy these things that are built just for the heck of it and the builder does not take him/herself too seriously.
You will want to check out a blog I've been following for years. Starting as a 'simple' hobbiest, and now having graduated to making enough money building replica gadgets as a professional Prop creator; http://volpinprops.blogspot.com/2010/07/daft-punk-final.html
Tends to include complete parts, manufacturing methods, photos, and electronics information on nearly all of this projects, including his Daft Punk replica helmets (one is nearly identical to the original that this entry was emulating).
This is the best written and most thoroughly analyzed project I've seen in this series. I'm comparing that to the college projects and the senior engineers that have presented on here! Great job! You'll be a major asset to some big corp someday, or blaze your own trail of success!
Bondo was cool, Chuck. When I was young, I worked in an automaotive store that sold Bondo. A lot of lazy body guys would slap on tons of cheap Bondo rather than doing the more difficult work of pulling dents and smoothing the metal surface. That meant if you hit a good pot hole, whole chunks of Bondo would fall off your car.
That was a fun project! I'm sure he makes a big impression wearing that while on a DJ gig. It'd be fun to add some kind of voice-following algorithm to the display, so the visor looks like Kit, from the old Knight Rider TV show. Tack on a voice-altering chip and you could go totally robotic! That's the delight of projects like this -- it gets the imagination going.
Focus on Fundamentals consists of 45-minute on-line classes that cover a host of technologies. You learn without leaving the comfort of your desk. All classes are taught by subject-matter experts and all are archived. So if you can't attend live, attend at your convenience.