Introduction: Going Green Even Under the Sea: Make a Cardboard Octopus Costume.

Our teacher assigned us a group project to construct flat-pack, marine themed costumes made of cardboard. These costumes had to be sized to fit middle school aged children. Today many people are trying to go green, so to stick with this idea, the costume had to be made from only recycled cardboard. My group decided that the theme 'Invertebrates" would be a fun choice for this project. This theme offered a variety of marine life that could be easily recognizable to middle school aged child.

Design Brief:
 Given the specifications for the project and the decisions my group made, I decided to create an octopus costume for a middle school aged play. I choose the octopus because the animal was easily identifiable, easy to make, only need a few parts to construct and assemble, and be simple to put on and take off. 

Specifications:
- Must fit a middle school aged child
- Must be flat-pack, slotted construction
- Must be marine themed
- Must be safe for middle school aged children to wear

Limitations:
- Can only be made out of recyled cardboard

Material List:
(S1) Cardboard    (Size: 40"x53") (Note: there will be extra cardboard around the edges. this piece will be used for both pieces)
(T1) Cutting Mat
(T2) Utility Knife
(T3) Ruler
(T4) Pencil

Parts List:
(P1) Tentacle Belt
(P2) Head Piece

Step 1: Making Part 1: Cutting Out the Tentacle Belt Outline

1. Lay out the cutting mat (T1) on the floor.
2. Lay cardboard (S1) on top of the cutting mat (T1).
3. Draw out a 5 ¼”x36” rectangle using the pencil (T4). Use the ruler (T3) for exact sizes.
4. Draw out 21 ¾” long tentacles that are 1 ½” wide along the 36” side of the belt using the pencil (T4). The space between the tentacles should be 3” , but at the ends of the belt there should be 1 ½” of space. Use the ruler (T3) for exact sizes
5. Cut along the edges of the traced lines using the utility knife (T2). Make sure to move the cutting mat (T1) where you cut.

Step 2: Making Part 1: Cutting the Tentacle Belt Slots

6. Measure 1 ½” from the 5 ¼” side of the rectangle and ¾” from the top using the ruler (T3)an mark using a pencil (T4).
7. Draw a 3 ¾” vertical line using a pencil (T4) to draw and a ruler (T3) to measure starting from the point marked in the previous step.
8. Cut along this line using the utility knife (T2) on the cutting mat (T1).
9. Measure ¾” using a ruler (T3) from the other side of the rectangle and the same from the top using the ruler. Mark this point using a pencil (T4)
10. Draw a 3 ¾”x 1 ½” rectangle using the pencil (T4). Use a ruler (T3) to measure.
11. Cut along the edges of the rectangle using the utility knife (T2) leaving out the innermost side.
(optional) 12. Paint the tentacle belt blue/green/purple to give it a cartoon like feel. Make sure to paint both sides of the belt or else it will warp.

If the steps were followed correctly then you should have the finished tentacle belt.

Step 3: Making Part 2: the Head Piece

1. Draw a 22” diameter circle using a pencil (T4) on the remaining cardboard (S1).
2. Cut out the circle using the utility knife (T2).
3. Draw a 5” diameter circle 11” away from the inside edge of the circle using a pencil (T4) to draw and a ruler (T3) for exact measurements. Note the edge of the inner circle will pass through the center of the outer circle, and this circle will not be cut
4. Measure 2” from the center of the circle to the point of intersection of the edge of the inner circle using the ruler (T3). Mark using the pencil (T4)
5. Repeat step 4.
6. Draw a line from the center of the inner circle using a pencil (T4) through the point found in steps 4 and 5.
7. Extend the line to the edges of the outer circle.
8. Cut along these lines using the utility knife (T2), creating tab 1. Make sure to cut on the cutting mat (T1).
9. Mark with the pencil (T4) 1” away from tab 1 along the edge of inner circle. Use the ruler (T3) for exact measurements
10. Mark using the pencil (T4) 4” away from the tab along the edge of outer circle using the ruler (T3) to measure.
11. Draw a line using the pencil (T4) connecting the points in steps 9 and 10
12. Cut along this line using the utility knife (T2), creating tab 2. Make sure the cutting mat (T1) is under where you cut.
13. Mark using the pencil (T4) 4” away from tab 2 along the edge of the inner circle using the ruler (T3) for exact measurements.
14. Mark using the pencil (T4) 18” away from tab 2 along the edge of the outer circle using the ruler (T3) to measure.
15. Draw a line connecting the points using a pencil (T4) in steps 13 and 14.
16. Cut along this line using the utility knife (T2), creating tab 3.
17. Mark using the pencil (T4) 2” away from tab 3 along the edge of the inner circle using the ruler (T3) to measure.
18. Mark using the pencil (T4) 7” away from tab 3 along the edge of the outer circle using the ruler (T3) to measure.
19. Draw a line using the pencil (T4) connecting the points in steps 17 and 18
20. Cut along this line using the utility knife (T2), creating tab 4
21. Repeat steps 9-16 on the opposite side of tab 1.
22. Cut a 2” slot on tab 1 using the utility knife (T2), 1” away from both edges.
23. Repeat step 22 on the opposite side of tab 1.
24. Repeat steps 22 and 23 on tab 4.
(optional) 25. Paint the tentacle belt blue/green/purple depending on the color painted on the tentacle belt. Make sure to paint both sides of the belt or else it will warp.

If the steps were followed correctly then you should have the finished head piece.
Now all that is needed is assembly. Note that the tentacle belt and head piece will not be connected.

Step 4: Assembling the Tentacle Belt (P1)

1. Wrap tentacle belt (P1) around waist.
2. Insert tab of the tentacle belt (P1) into the slot on the other end of the tentacle belt (P1).
3. Rotate the tentacle belt (P1) around the waist so the slot is not visable

Step 5: Assembling the Head Piece (P2)

1. Insert edges of the largest tabs (tab 3 and its corresponding tab on the opposite side) of the head piece (P2) into the slots closest to each of them (in tabs 1 and 4). Make sure the tabs not being used are tucked under the tabs so they are not seen (tab 2 and its corresponding tab on the opposite side).
2. Place the head piece (P2) on head so that the inner circle is farther back.

This concludes the making and assembling of the octupus costume

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