Design Brief: Design and build a costume made of only recycled cardboard using slotted construction. Costume must fit an Intermediate school child, be worn with minimum supervision, and be easily constructed. The costume will be flat packed, easily transported/stored, and use only slotted construction.
This costume will be able to be constructed by anyone that is looking to find a cardboard costume. This costume is meant to be a stage costume, because it is not practical for running around and trick-or-treating. Though this costume is not meant for agility it does present the maximum range of motion because it is in two parts. As opposed to being only one piece and not allowing one to bend or move their legs. This costume, having separate torso and leg pieces, allows one to bend and move legs to a certain extent. The average 11-12 year old female student is between 50-60 inches, while the average male student is 50-70 inches. This was considered while designing the costume but there is room for alterations if needed.
For this costume we could only use recycled cardboard, from warehouses for example. The costume would need to be feasible for a student to be able to wear, be comfortable, and be able to assemble or disassemble with ease. Bot being able to use tape or glue was a set back but slotted construction makes it easier to reuse the costume. How much cardboard the costume would be using was also a concern because there is not always large strait pieces of cardboard on hand.
Item Material Description Qty Size Remarks-Parts
S1 Refrigerator Box 1 Will cover whole costume
Step 1: Box
Step 2: Mask
This circle will become the mask once a face is drawn, you may draw the face using my design or using your own.
Step 3: Cutting Out Mask
Also cut out both eye holes and two 2in. slits on either side of the mask.
Step 4: Head and Hand Straps
Cut out all three straps with a utility knife(T2).
Once cut out bend the straps in multiple places vertically to round them so that they will fit to your head and hands comfortably. Use the divots already in the cardboard as guides.
Note: Straps can be lengthened or shortened to better fit the wearer.
Step 5: Rectangles
Step 6: Small Flippers
Once the flippers are done to your satisfaction cut the flippers out with a utility knife(T2) or scissors. Inside the flippers make two 2in slots on either side
Step 7: Torso
The first section will be 16in long, then 8in, then 16in, and finally 8in. On the far right side there will be two 4inX4in tabs that start 4in from the top and have 4in. in between them.
In both 8in sections, from the center, go up 8in from the bottom using a ruler(T3). This is where the 6inX8in circle will be located, you may use a circle template(T5) to make circle.
Finally on the last section on the left side draw two 4in slits that correspond with the tabs on the opposite side.
Step 8: Cut Out Torso
Step 9: Arms and Slits
Step 10: Round Corners
Step 11: Tail Fin
First section will be 9in, then 12in, then 9in, and finally 12in. On the far left side there are two 4inX4in tabs. The tabs start 8in. from the top left corner and 4in in between.
Draw each section, including the 4in section to the left, all the way down the cardboard.
-Inside the 4in section go down 4in and draw a 4inX4in square then do the same 4in down.
-In the first 9in section go down 4in and draw a horizontal line through the hole section. Then from bottom of the second tab draw a 4.5in line, from there go diagonally up to the 12in section.
-In the first 12in section draw a tail fin that fits to the section, see picture.
-In the second 9in section draw a line 4in down across the whole section. From there go 6in down on either side and draw diagonal lines that meet 16in down from the top of the cardboard.
-Finally in the last section draw a tail fin the same as the first 12in section.
Step 12: Cut Out Tail
Step 13: Parts List
P1 1 Mask
P2 1 Tail Fin
P3 1 Torso
P4 2 Small Flippers
P5 1 Head Band
P6 2 Hand Band