Picture of Tin Man Costume On The (not so) Cheap
I volunteer with my church to act as different characters for their vacation bible schools and "trick or treat street"s. Trick or treat street is a family friendly trick or treat alternative in e safe environment for the kids in my community. This upcoming summer I will be portraying the tin man in our VBS week of "The Wizard of Oz", consequently I am also designated tin man for the trick or treat street Wizard of Oz room. Here's how I made my costume in less than 1.5 weeks.
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Step 1: Materials

Picture of Materials
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13, 11:24 AM.jpg
13, 11:24 AM.jpg
The materials I used:
Foam EVA Puzzle piece mat
Craft Foam Sheets (8"x12")
Duct Tape
Hot glue
Old shirt
Old thin jacket
Old jeans
Pair of shoes you don't mind "improving"
Pair of gloves you don't mind "improving"
Wooden dowel or plunger handle
Aluminum metallic Rustoleum spray paint (3 can)
Steel Gray Plasti-Dip (2 can)
Hot glue gun
Box cutter

Step 2: Get Inspired!

Picture of Get Inspired!
13, 11:24 AM.jpg
13, 11:24 AM.jpg
13, 11:24 AM.jpg
13, 11:24 AM.jpg
13, 11:24 AM.jpg
13, 11:24 AM.jpg
13, 11:24 AM.jpg
13, 11:24 AM.jpg
Look up pics or videos of tin man to get inspired! Here are some I used.

Step 3: The Cylinder

Picture of The Cylinder
Fingered out how much foam you need to go all the way around your upper body, I was lucky as two, 2' x 2' squares worked for me! I put them in a cylinder (harder than it sounds), used the straight edges that came with them (had to trim one), and then had a cylinder!

I duct taped the pieces together to make sure they stayed.

Step 4: Arm And Head Holes

Picture of Arm And Head Holes
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Obviously I needed a place to stick my arms out, so I measured and cut two holes larger than my arms on either side. I also cut a piece from a different foam mat square to put in the top, and cut a hole for my head before taping that piece on the top of the cylinder.

Step 5: Hide The Tape!

Picture of Hide The Tape!
13, 11:24 AM.jpg
13, 11:24 AM.jpg
I hid the tape by cutting the foam sheets in half length-wise, giving me two ~4" x ~12" strips of foam, and did my best to cover all the duct tape, and the entire top of the torso! I applied the foam sheets with some hot glue