Halloween is right around the corner, and you don't have a costume ready! You don't want to spend big bucks on something fancy you'll only wear once! And you don't want to get lost in a sea of junk at the thrift store!
Now there's a better solution! That's right: instead of watching TV, you can be TV! Amaze your family! Delight your friends! Impress your co-workers! Just follow these easy, simple instructions:
Step 1: Step 1!
Because of the weird, cartoony, retro shape and angles, I first made test sketches and a small 1/8 scale version to see how everything would fit together. This allowed me to avoid the application of trigonometry. The weird shape is optional, and a normal, rectangular TV design works also.
I also wanted to make the full-size box fold up flat, so the scale version also let me test that out.
For the full-size version, I put to use several large sheets of leftover bristol board. I later got blue cardstock to put on top of them for the exterior color. Either material would've worked on its own, since it would be sturdy enough when folded into a box. And it'd make the costumer lighter. Of course, you could also use corrugated cardboard, posterboard, or foam core.
For an average-sized head like mine (hat size is ~7 1/4), and this particular shape, the dimensions worked out to this:
11.5" max height, 10.5" up the middle
14.5" max width
Front panel is 10" along bottom edge, 14" top, 10" left, 12" right.
Making your own will require a lot of trial and error. When trying to narrow down the fit, I used some old calendar sheets and low-tack tape. I also went for a slightly snug fit so it wouldn't wobble too much, but I later came up with some last-minute braces (step 4).