That's not nerd. That's awesome.

Personally, I wouldn't make the horns out of metal. Weights too much. I'd personally use paper pulp: http://en.wikipedia.org/wiki/Pulp_(paper) and reinforce it with glue once it has dried into the shape you want it. After that, paint it in any fashion you want, and once against cover it with clue. Should be light, but not fragile.