Introduction: Constructed Cardboard Creature: Narwhal

This costume was a school project. Cardboard is the only material used for the body of costume. The project was to create a line of marine themed costumes. The costumes were either Halloween costumes or stage costumes. The costumes were for middle school aged children. This narwhal costume is from a line of Marine Mammal costumes. Different groups in the class had different themes. 
I designed and created a Narwhal stage costume. The only material used was cardboard. I researched the target audience, which was middle school aged children. I had to understand what the audience liked to wear and average body measurements. Slotted construction and Flat Pack Design was used for assembling the costumes. 

• double ply or single-ply cardboard
• fit middle school aged child
• slotted construction
• flat-pack design
• resemble a marine organism or marine related structure

• recycled cardboard only, no fasteners. 
• able to be worn as stage costume or Halloween costume

Step 1: Materials

For this costume, the following is needed:
• 30in x 45in 2-ply Cardboard Window Box (Quantity: 2)
• 18in x 36in 2-ply Cardbaord Window Box (Quantity: 2)
• Cutting Mat
• Utility Knife
• Ruler 
• Pencil
• Circle Template or Compass
• Packing Tape

Step 2: Producing Body(P1)

Use ruler (T3) and pencil (T4) to measure 26in across top of piece from edge of cardboard. Measure 10in down side of cardboard, leaving 2in of space between the line and the edge of the cardboard. Mark this location with pencil (T4). Measure outwards 2in parallel to top. Measure 1in along edge of cardboard. Measure back another 2 inches, creating a tab on the side of the costume. Repeat this step 2in lower on the cardboard. Measure downward another 10in, making sure to trace with pencil (T4). Mark this location. 
Along the initial top line, measure across 24in. Repeat the steps to create another two tabs. At the bottom of each side, draw fins or flippers. Use packing tape (T6) to fix any unwanted slits. 
Use utility knife (T2) to cut along outline on top of cutting mat (T1). 

Repeat for back (P2)

Step 3: Producing Sides(P3)

Use ruler (T3) and pencil (T4) to measure a 18in x 36in rectangle. Use a 6in diameter circle template (T5) and pencil (T4) to measure an arm hole, 4in from top of the side (P3). Use utility knife (T2) to cut and remove arm hole on top of cutting mat (T1). Use utility knife (T2) to create two 2in slots on both sides of the piece. The slots should be 18in down from the top of the part, and 1in apart. Use utility knife (T2) to cut out the side (P3) on a cutting mat (T1). 

Repeat for Side 2 (P3)

Step 4: Parts List

Item: Part Name (Quantity)
P1: Front (1)
P2: Back (1)
P3: Side (2)

Step 5: Insert Front Into Side

Insert tabs a and b of Front (P1) into slots a and b of Side1 (P3). 

Step 6: Insert Front Into Side

Insert tabs c and d of Front (P1) into c and d Side2 (P3)

Step 7: Insert Back Into Side

Insert tabs a and b of Back (P2) into c and d of Side 1 (P3)

Step 8: Insert Back Into Side

Insert tabs c and d of Back (P2) into slots a and b of Side 2 (P3).

Step 9: Box Shape

The parts, when all assembled correctly, should form a box-like structure. 

Step 10: Putting on the Costume

Have a friend help you. Hold your arms above your head, while a very close friend lowers the costume over you. Slide your arms through the arm holes in the sides. The top part of the Sides (P3) should rest on your shoulders, supporting the costume. Bend as needed. 

Step 11: Have Fun in Your Narwhal Stage Costume!

Plan of Prodedures attached.