Robot Costume With LEDs

Step 2 Preparing the Head and Body

Your smaller box needs only five sides, not six. So pick the least appealing side of the small box and cut it off.

Your bigger box also only needs five sides, but cutting off may not be necessary. I extended the flaps that made up one side to make my big box bigger. However, if your box is the correct size without any extension, pick the least appealing side and cut it off.

For eyes, I cut an oval on one side the small box. I made an oval with length 5.5 inches and height 2.25 inches with the top of the oval 4 inches below the edge of the cardboard box. Any variation on eyes can be used, but make sure you can see out of your eye hole(s).

For the neck, I cut a square out of the side of the big box that I wanted to be the top. I cut a 10 inch by 10 inch square, or an area just slightly smaller than the size of my box for the head.

For arm holes, I measured the size of my duct and cut a comparable hole. You want the duct to fit snugly. I tried a number of locations, and it doesn't really matter where you put the holes. I cut my arm holes with the top of the hole about three inches below the edge of the box.