This project was a bit of a rush job in order to get it finished for Halloween last year but it turned out great and was allot of fun. The jack o' lantern was made of paper mache and a few other bits and pieces, painted with acrylic paint and had 15 red and yellow 5mm LEDs inside that were switched on and off randomly with a microchip. I'll explain briefly how I did it all below. Click the thumbnails to see a larger image.
I used a balloon to create a hollow form. Strips of newspaper were applied over the ballon using a paste made from flour and water. The mache ballon was placed on a plastic sheet so it wouldn't stick to the work surface as it dried. I tied strings tightly around the ballon to create segmentation lines, applied more paper over them and then I used an old broom stick wedged against the ceiling in my shop to create an indentation on top.
The mache pumpkin took several days to dry completely. Once dry, I glued a disk of thin plywood with a wire for hanging the pumpkin into the indentation on top of the pumpkin. I sandwiched the wire between two pieces of foam to simulate a stem and then applied more newspaper over the stem and lapping onto the pumpkin to secure everything in place. together.
After everything had dried thoroughly, I cut a face in the front and an access hatch on the back with a thin sharp blade. Craft acrylic was used on the outside of the pumpkin and cieling white was used inside.

While I had dabbled from time to time with solar panels and low voltage eletronics this was to be my first time messing around with microcontrollers. I had played around a bit programming them and switching LEDs but I needed something a little more advanced than my ability fast and found the program I needed at http://www.r4nd0m.com/Candle.html

The program was written in C for a PIC12F675. It switched 5 LEDs randomly to simulate a candle flame this did not produce enough light for what I wanted to do so I set my circuit up to switch 15 LEDs. I soldered together 5 sets of three 5mm LEDs in parallel and connected them to the 5 pin outs of the PIC12F675.

Since this was intended to run all night, I powered it with a 7.5V power supply I had in my junk box. I used an LM317 to drop the voltage down to 3.5V. I used the highest MCD rated LEDs I could find locally and by arranging them so that they threw light into each other I gained a bit more brightness. Here is a a short .avi of how the LEDs looked when set up on a breadboard.