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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
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.
<p>I made this costume based on your instructions - it was a fun project and I ended up winning the costume content as work!</p>
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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