Design Brief : Design and build a sturdy, slotted construction costume made solely out of cardboard without any adhesives. To have the final costume be durable, flat pack, and be able to be used easily for middle school aged children.
Created only out of cardboard
Must be Marine themed
Easily put together with minimal supervision
Be sturdy and durable
Made only with cardboard
Flat pack construction
Cardboard availability and sizes
Step 1: Materials and Tools
S1 REFRIGERATOR BOX (DOUBLE PLY) 72"X36”
S2 FLAT SCREEN TV BOX 18"X32”
S3 CARDBOARD SHEET 40"X9”
S4 CARDBOARD SHEET 12"X18”
T1 CUTTING MAT: Aids cutting the cardboard sheets so that the floor/work surface is not cut underneath
T2 UTILITY KNIFE: Cuts the shapes out of cardboard easier than scissors
T3 THREE FOOT RULER: Allows accurate measurements of the larger pieces
T4 PENCIL: Draw and mark the shapes needed to cut out
Step 2: Creating the Body
Step 3: Body
Step 4: Body
5. Then, from the bottom right hand corner, measure (T3) 12” upwards (from the bottom) and draw (T4) a horizontal line lengthwise over the entire rectangle.
6. Now there should be four 18” panels with a line running across horizontally 12” up from the bottom.
7. Mark (T4) the center of each 18” segment along the bottom.
8. Draw (T4) 2 diagonal lines extending from the center mark in opposite directions, so that they form a triangle facing downwards.
9. Repeat this step for all of the four panels.
Step 5: Creating the Armholes
11. Repeat this on the opposite panel. These shapes are the armholes.
Step 6: Slot
2. Cut this line using utility knife (T2) so that the line can be the slot.
3. Repeat on the opposite panel.
Step 7: Finishing the Body
Step 8: Creating the Lid
2. Measure (T3) 6” horizontally inward from the each top corner of the rectangle. Mark using pencil (T4).
3. Extend these lines downwards so that the cardboard is divided into 3 sections, the middle one being 18"X18”.
4. Mark (T4), the center of the middle panel, measure (T3) and draw (T4) a 9X9” square around the center point.
5. Cut the square out using the utility knife (T2).
6. Score (T2) the two vertical lines that are 6” in from each side using utility knife.
Step 9: Creating the Slotter Piece
2. Cut it out using the utility knife (T2).
3. Score, using utility knife (T2), the rectangle down the middle (9” in from both sides).
Step 10: Creating the Headpiece
2. Measure (T3) along the top vertically and mark with pencil (T4) every 9”. Repeat along the bottom as well. This will divide the rectangle into five sections (4 equal one smaller).
3. Extend the lines vertically downwards and attach to bottom marks; this will leave an extra 4” for the slotted piece.
4. On the 4” slot, measure (T3) two inches down or up from each of the two corners.
5. Cut (T2) the 2” piece off so that the slot now measures 8X4”.
Step 12: Parts List
ITEM QTY PART NAME
P1 1 Body
P2 1 Lid
P3 1 Slotter
P4 1 Headpiece
Step 13: Final Assembly
2. Insert the slotter (P2) into the designated slots on the Body (P1). This should secure the box.