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!

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
  • 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.


Can you show the back of the circuitry board by chance the soldering connections. I'm trying to build it for my daughters costume and I am very novice to circuitry but I can replicate it by a pic. And by the way every costume you guys do ROCK..... Thanks
Wow, this is the best costume I've seen. I hope you'll win!
Very cute, and so simple. Thanks for sharing.
yes! This is my absolute favorite robot costume on the site. :D I'm happy to see it documented more fully!

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More by toonmusic:Voice Changing Robot Costume w/ animated mouth Awesome Lego Indiana Jones Costume Kids Voice Changing Robot Costume 
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