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Introduction
My technology teacher gave my class a project where we have to design and build a costume with a marine theme.
The costume has to be a marine themed, slotted, flat-pack costume for a middle school student to wear on Halloween or for a stage performance. The costume is also eco-friendly because it is made out of 100% recycled cardboard.

Design Brief
Based on the “Being Green” concept, develop a marine themed costume made from recycled cardboard that can be slotted together for assembly that adults can easily make for middle school aged children to use indoors or outdoors under minimal supervision.

Specifications
The costume must be made entirely out of cardboard. The pieces must be assembled by slotted construction only, so no fasteners or adhesives are allowed. The costume must be able to fit the average child between the ages of 10-13, and must be safe for all ages. The costume will be flat-pack, meaning the pieces will appear flat when disassembled, for easy storage.

Limitations
The costume cannot limit a child’s peripheral vision, mobility, or aeration. The costume must be appropriate and safe enough for the child to wear it with little to no supervision.

Materials List
Supply List
S1: Cardboard (1) 2.25’ X 1.5’ - Head
S2: Cardboard (2) 7” X 1” - Head Connector
S3: Cardboard (1) 6’ X 1.5’ - Body
S4: Cardboard (2) 1’ X 2’ - Side of Shell
S5: Cardboard (1) 1’ X 2’ - Shell Connector
S6: Cardboard (2) 3” X 11.25” - Eyes

Tools and Equipment List
T1: Cutting Mat
T2: Utility Knife
T3: Ruler
T4: Pencil

Step 1: Body

Body
All cutting is done on a cutting mat (T1)
Be sure to read each step through before you do it.
1. Measure and score a 6’x1.5’ piece of cardboard using a ruler (T3), pencil (T4), and utility knife (T2).
2. Draw a dotted line in the very center of the cardboard using a pencil (T4) so that there are two 3’x1.5’ rectangles. Do not cut through this line
3. Fold the cardboard downward on the line you just drew.
4. Draw two new lines on either side of the previous line with a pencil (T4), each line exactly 5 inches away from the center line.
5. Fold the cardboard upward on each of the two new lines, so that when all three lines are folded, a zig-zag figure is created.
6. In the center of the rectangle formed by the three lines, draw and cut a 9”x9” square using a pencil (T4) and a utility knife (T2). The square should cut through the middle line. This square creates the hole in which your head will go through. Make changes to the square if necessary to fit your head.
7. Now there should be two 2.5’x1.5’ rectangles on either side of the three lines and head hole. Decide which rectangle will be the front, and which will be the back. On the back side, draw and score two identical 2’ lines perpendicular to the three lines from steps 2-4, using a pencil (T4) and a utility knife (T2). Make sure the lines are as thick as the cardboard you are using for they are slots for another two pieces of cardboard.

Step 2: Head

Head
All cutting is done on a cutting mat (T1)
Be sure to read each step through before you do it.

1. Measure and score a 2.25’x1.5’ piece of cardboard using a ruler (T3), pencil (T4), and utility knife (T2).
2. Draw two vertical lines, each exactly 3/8’ away from the nearest side, using a ruler (T3) and a pencil (T4), so that there are three rectangles going down when the cardboard is turned vertically.
3. Then turn the cardboard horizontally, and draw two vertical lines each 9” away from the nearest side using a ruler (T3) and a pencil (T4). This should create a grid pattern.
4. Keeping the cardboard horizontal, score the lines outlining the two middle rectangles on the top and bottom of the center square using a utility knife (T2).
5. On the top two rectangles on the left and right of the now empty space, draw and score one flap on the top inner corner of each rectangle using a pencil (T4) and a utility knife (T2). The flaps should be shaped almost like a U, and should point to the lower, outer corner.
6. Repeat step 5, only the flaps should be on the lower inner corner, facing the top outer corner.
7. Draw and score two 3” vertical lines, using a ruler (T3), a pencil (T4) and a utility knife (T2), in the center of the center square, one line on top of the other, about 2 ½ inches apart. Leave about ½ an inch between each line and the edge of the square.
8. Draw and score an 8”x8” square inside the square on the left of the center square using a ruler (T3), a pencil (T4), and a utility knife (T2).

Head Connector
All cutting is done on a cutting mat (T1)
Be sure to read each step through before you do it.
1. Measure and score two 1”x7” pieces of cardboard using a ruler (T3), a pencil (T4), and a utility knife (T2).
2. Draw and score a slanted line from both bottom corners of each piece to about 1 inch in on the top using a pencil (T4) and a utility knife (T2).
3. Take the two sides of each piece and fold them inwards, creating a crease about an two inches from the sides.

Step 3: Shell

Sides of Shell
All cutting is done on a cutting mat (T1)
Be sure to read each step through before you do it.
1. Measure and score two identical 1’x2’ pieces of cardboard using a ruler (T3), a pencil (T4), and a utility knife (T2).
2. Using a pencil (T4) and a utility knife (T2), draw and score a curved line the starts at the top left corner of the cardboard, meets at the center of the long right side, and ends at the bottom left corner of the cardboard. This creates the shape of the shell.
3. Using a pencil (T4) and a utility knife (T2), draw and score a second curved line starting 3 inches underneath and to the right of the top left corner, continuing 3 inches under the edge of the curve, and ending 3 inches above and to the right of the bottom left corner. Make sure this curved line is as thick as the cardboard you are using for this is a slot for another piece of cardboard.
4. Repeat steps 2-3 on the second 1’x2’ piece of cardboard.

Shell Connector
All cutting is done on a cutting mat (T1)
Be sure to read each step through before you do it.
1. Measure and score a 1’x2’ piece of cardboard using a ruler (T3), a pencil (T4), and a utility knife (T2).
2. Lightly fold the piece of cardboard numerous times so that it is curved vertically.

Step 4: Eyes

Eyes
All cutting is done on a cutting mat (T1)
Be sure to read each step through before you do it.
1. Measure and score two identical 1’x3” pieces of cardboard using a ruler (T3), a pencil (T4), and a utility knife (T2).
2. Using a pencil (T4) and a utility knife (T2), draw and score a 5”x5” circle touching the top of the piece of cardboard, a 6”x2” rectangle attached to the bottom of the circle, and a ½”x3” rectangle perpendicular to the other rectangle attached to the top of it. This figure should create the eye.
3. Draw a smaller circle using a pencil (T4) inside the large circle to create the pupil of the eye.
4. Repeat steps 2-3 on the second piece of cardboard.

Step 5: Assembling the Body

Parts List
P1: Head (1)
P2: Head Connector (2)
P3: Body (1)
P4: Shell Slides (2)
P5: Shell Connector (1)
P6: Eyes (2)

Assembling the Shell
Be sure to read each step through before you do it.
1. Insert the shell connector (P5) into the slot in one of the shell sides(P4).
2. Insert the other side of the shell connector (P5) into the other shell side (P4).

Assembling the Body
Be sure to read each step through before you do it.
1. There should be a bit of the straight edges of the shell sides (P4) sticking out before the edge of the shell connector (P5) interrupts it. Insert that side of the shell into the slots in the back of the body (P3).

Step 6: Assembling the Head

Assembling the Head
Be sure to read each step through before you do it.
1. Take the two rectangles on the top, and the two rectangles on the bottom, and fold them all inward.
2. Take the square on the left, and the square on the right, and fold them in towards the center square.
3. Insert each head connector (P2) into the two flaps on each side, so that both sides of one connector are inside either flap, holding the head (P1) together.
4. Insert each eye (P6) into one of the two slots on the top of the head (P1). Make sure that the eye is not pushed all the way in, but that the top of the bottom rectangle on the eye (P6) is touching the roof of the head (P1).

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