Things You'll Need
Large plastic hair rollers, 2 bags
Shower cap with wide elastic band
Pliable copper wire
Medium grade sandpaper, 3 large sheets
Silver spray paint
The iconic Pink Ladies wore their rollers well. While there are several pre-made "Grease" costumes available online or in seasonal Halloween shops, they can run up to $50, at 2011 prices, and lack the personal creative touch. For a hand-crafted look you can boast at any costume party, start with a short, silver, over-sized T-shirt-shaped dress from a vintage or thrift store. You're due bonus points if it sparkles. The headdress will take a bit longer but can be made by anyone.
Construct the triangular structure framework from bendable copper wire, which you can buy cheaply at any hardware store. For the base, wrap a piece of wire around your head. Make sure to wrap exactly where the headdress will sit securely. Triple the wire of the circle for strength, and add pieces of wire every three inches or so around the circle. The pieces can be as long as you want, depending on how tall you'd like the headdress to be. They probably shouldn't exceed 10 to 12 inches. Once these pieces are attached, construct a wire circle to join them at the top. It should be small enough to create the triangular shape, but large enough to maintain balance between the bottom and top of the frame.
Give the frame more stability with pieces of sandpaper. Hold a sheet of scrap paper to each open space between the sets of wires, and trace the shape, which should resemble a triangle, but will differ slightly with each space. One by one, trace the scrap shapes onto the sandpaper and cut it out. Use gorilla glue to attach the sandpaper to the wire frame, slowly closing the gaps, including the open top circle. The frame is now enclosed and sturdy.
Glue the hair rollers horizontally in one column on the front and back, all the way to the top of the headdress. Glue them vertically in rows on the sides of the frame, and place them diagonally anywhere there is an open space left.
When the glue dries, spray paint the entire thing silver. Make sure to do it outside, with good ventilation, and get the paint into all nooks and crannies. It may take a few coats, and it's more difficult to paint once it's already constructed--but painting first makes the glue less effective, creating a less reliable frame. Spray paint the shower cap as well.
For added effect, cut aluminum foil into strips to run snugly over the front and back rows. The foil can be glued on once the spray paint dries. When you're ready to wear the headdress, put on the shower cap and pull the circular wire frame down over the cap's elastic band. Only the silver elastic band should be showing. This padding will help keep the structure secure.
For added security, glue the wire base to the shower cap elastic band.
Bring gorilla glue to the party in the case of a loose roller.
If you want to experiment with materials other than sandpaper, such as bendable honeycomb or shape-retaining plastic, visit Inventables.com for ideas.