Voice Changing Robot Costume w/ animated mouth

We made this robot costume about 3 years ago for our 7 year old at the time, and posted a photo of it here last year. Since then I've received numerous requests to explain how it was done in a step by step. I still have most of the robot sitting in my office, so I took some more photos, and dug up some schematics so you get a better idea of how you can make your very own!

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Step 1: The anatomy of a robot

Here's what you need:

For the BODY

Numerous cardboard boxes of various sizes for head, body, and feet.
2 or 3 rolls of aluminum foil tape used in duct installation. Like this.
Metal dryer duct. (Size dependent on size of arms and legs of wearer)
Black cotton gloves
Material for antenna... we used shavings from a pipe threader
2 aluminum cans
Black turtleneck shirt, or a black neck gaiter to hide the wearer's neck.
Hot glue

For the ELECTRONICS

1 - Velleman Voice Changer kit. I got mine HERE.
20 clear lens LEDs (color is your preference, but you'll want a clear lens to make the unlit ones more discreet)
1 Small speaker
Resistors of the following quantities and values:
10- 330 ohm (9 for mouth, one for eyes)
1 - 470 ohm
1 - 1K ohm
1 - 2.2K ohm
3 - 4.7K ohm
3 - 10K ohm
3 - 33k ohm
2 - 39k ohm
2 - 47k ohm
1 - 100k trim pot
10 NPN Transistors
1 PNP Transistor
2 - 22uF electrolytic capacitors
2 - 4.7uF electrolytic capacitors
9 - 1N4148 or similar diodes
scrap ribbon cable and hook up wire

The most important thing is to be creative, and willing to improvise with the materials you have on hand.