Join Date: Feb 2005
Location: It is a mystery.
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Cut out leaves from some kind of spongy foam. It would be light-weight enough to wear on his head without being cumbersome and soft enough that it wouldn't hurt anyone he might bump into. It would be stiff enough to stick up without wires too- especially if you doubled it by gluing two cut-outs together. (Spray adhesive would be good for that.)
I'm thinking you'd be able to get something like that at a craft store, but a moving supply place might have it too. I think your chances of finding it in green are pretty good, but it should also spray-paint fine if you give it a few days to dry.
You might even be able to find some of that egg-crate sponge that people put on top of their mattresses and use to sound-proof rooms.
Homeschooling, etsy-crafting Mama to spunky DD (12-04) and wife to DH.