Cardboard is a material that can do more than just store junk. For a school project, a costume had to be designed using cardboard and slotted construction. The costume also belonged to a line of costumes with a similar marine theme. Going green was also a theme for this project. The next part of this task was to post said costume design on Instructables. A step by step format accompanied with pictures was the format designated for the project.
Hermit Crab Design Brief
I had to design a costume made entirely of cardboard that was held together with only slotted construction. The costume also had to be a part of a group that other members of my team designed.
Hermit Crab Specifications
- The costume must be marine themed.
- The costume must fit into the group theme.
- The costume must be designed for children between 10 and 13 years old.
- The costume must be flat packable
Hermit Crab Limitations
- The costume can be made of only cardboard
- The costume parts can only be attached with slotted construction
- No tape can be used
- The costume must use easily obtained cardboard
What You Need
Supply list
S1- TWO PLY, LARGE CARDBOARD SHEET TO CUT SHELL AND BODY PARTS OUT OF.
1 25IN.X25IN.
THIS CARDBOARD SHOULD BE TWO PLY. IT IS DIFFICULT TO CUT BUT STURDY.
S2- ONE PLY CARDBOARD SHEET TO CUT BODY PIECE CONNECTORS OUT OF.
1 35IN.X8IN.
THIS CARDBOARD SHOULD BE THIN BECAUSE THE CONNECTORS WILL NEED TO BE FLEXIBLE.
The cardboard needed can be appliance or furniture boxes.
Tools and Equipment list
T1- CUTTING MAT
PLACED BELOW CARDBOARD WHEN CUTTING TO PREVENT SCRATCHING SURFACES BELOW THE CARDBOARD.
T2- UTILITY KNIFE
CUT COSTUME PARTS OUT OF THE CARDBOARD SHEETS.
T3- RULER
MEASURE THE PARTS OF THE COSTUME WHEN DRAWING THEM TO MAKE THE PARTS THE PROPER SIZE.
T4- PENCIIL
DRAW EACH PART NEEDED TO ASSEMBLE THE COSTUME.
PART LIST
P1- x1 SMALL SHELL
P2- x1 MEDIUM SHELL
P3- x1 LARGE SHELL
P4- x1 BODY PIECE- BACK
P5- x1 BODY PIECE- FRONT
P6- x6 BODY CONNECTOR
(See Plan of Procedures document for more information)

Plan of Procedures no pix.docx
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Step 1: Preparing the Small Shell (P1)

Dimension and draw a 9’’x2’’ rectangle with the ruler (T3) and pencil (T4) on the cardboard sheet (S1). Dimension and draw the flaps on the sides of the rectangle using the ruler (T3) and pencil (T4) on the cardboard sheet (S1). Place the cutting mat (T1) down and cut along the outline drawn with the utility knife (T2). Fold the flaps down where they meet the rectangle.

Step 2: Preparing the Medium Shell (P2)

Dimension and draw a 6’’x12’’ rectangle with the ruler (T3) and pencil (T4) on the cardboard sheet (S1). Dimension and draw the flaps on the sides of the rectangle using the ruler (T3) and pencil (T4) on the cardboard sheet (S1). Measure and draw the slots in the center of the rectangle with the ruler (T3) and pencil (T4). Place the cutting mat (T1) down and cut along the outline drawn with the utility knife (T2). On the cutting mat (T1) cut out the slots with the utility knife (T2). Fold the flaps down where they meet the rectangle.

Step 3: Preparing the Large Shell (P3)

Dimension and draw a 10’’x17’’ rectangle with the ruler (T3) and pencil (T4) on the cardboard sheet (S1). Dimension and draw the flaps on the sides of the rectangle using the ruler (T3) and pencil (T4) on the cardboard sheet (S1). Measure and draw the slots in the center of the rectangle with the ruler (T3) and pencil (T4) Place the cutting mat (T1) down and cut along the outline drawn with the utility knife (T2). On the cutting mat (T1) cut out the slots with the utility knife (T2). Fold the flaps down where they meet the rectangle.

Step 4: Preparing the Body Piece- Back

Dimension and draw a 14’’x21’’ rectangle with the ruler (T3) and pencil (T4) on the cardboard sheet (S1). Measure and draw the slots in the center and along the sides of the rectangle with the ruler (T3) and pencil (T4). Place the cutting mat (T1) down and cut along the outline drawn with the utility knife (T2). On the cutting mat (T1) cut out the slots with the utility knife (T2).

Step 5: Preparing the Body Piece- Front

Dimension and draw a 14’’x21’’ rectangle with the ruler (T3) and pencil (T4) on the cardboard sheet (S1). Measure and draw the slots along the sides of the rectangle with the ruler (T3) and pencil (T4). Place the cutting mat (T1) down and cut along the outline drawn with the utility knife (T2). On the cutting mat (T1) cut out the slots with the utility knife (T2).

Step 6: Preparing the Body Connectors

Dimension and draw six 2’’x15’’ rectangles with the ruler (T3) and pencil (T4) on the cardboard sheet (S2). Place the cutting mat (T1) down and cut along the outline drawn with the utility knife (T2).

Step 7: Assembling the Shell Pt.1

Take the flaps from the small shell (P1) and insert them into the corresponding slots on the top of the medium shell (P2).

Step 8: Assembling the Shell Pt.2

Take the flaps of the medium shell (P2) and slide them into the corresponding slots on the top of the large shell (P3).

Step 9: Connecting the Shell and Body

Insert the flaps from the large shell (P3) into the corresponding slots in the center of the body piece- back (P4).

Step 10: Connecting the Body

Take the six body connectors (P6) and insert them into the slots along the bottom, outer section of the body piece- back (P4). Line up the body connectors with the slots on the body piece- front (P5) and slide them into the corresponding slots. The costume is complete and can be decorated if you would like. PAINT BOTH SIDES OF THE CARDBOARD OR IT WILL WARP.