Introduction: Creating a Cardboard Buoy!

The marine themed costume project was assigned by our school, and inspired by the theme "Going Green".  The instructions were to create a costume using only cardboard.  The costume could not have tape, glue, or adhesives.  The costume also had to be flat pack construction and had to fit together by slotted construction.  The assembly had to be easy, with minimal adult supervision and help.  The target audience were middle schoolers, and we had to design either a stage costume or a Halloween costume.  Our group chose marine themed objects that were red, and a buoy popped into my mind.  

Design Brief : Design and build a sturdy, slotted construction costume made solely out of cardboard without any adhesives. To have the final costume be durable, flat pack, and be able to be used easily for middle school aged children.

Specifications :
Created only out of cardboard
Must be Marine themed
Easily put together with minimal supervision
Be sturdy and durable
Made only with cardboard
Flat pack construction
Slotted Construction
No adhesives

Limits :
Cardboard only
Slotted Construction
Flat pack
No adhesives
Cardboard availability and sizes

Step 1: Materials and Tools

Materials :
S2 FLAT SCREEN TV BOX                             18"X32”
S3 CARDBOARD SHEET                                40"X9”
S4 CARDBOARD SHEET                                12"X18”

Tools :
T1 CUTTING MAT:  Aids cutting the cardboard sheets so that the floor/work surface is not cut underneath
T2 UTILITY KNIFE: Cuts the shapes out of cardboard easier than scissors
T3 THREE FOOT RULER: Allows accurate measurements of the larger pieces
T4 PENCIL: Draw and mark the shapes needed to cut out

Step 2: Creating the Body

1. Lay cardboard (S1) out and measure (T3) a 72"X36" rectangle, cut this shape out using the utility knife (T2).

Step 3: Body

3. Measure (T3) lengthwise, every 18” along the top and the bottom; mark with pencil (T4). These will be the four panels for the body.

Step 4: Body

4. Connect the panel lines to the bottom edge of the cardboard.
5. Then, from the bottom right hand corner, measure (T3) 12” upwards (from the bottom) and draw (T4) a horizontal line lengthwise over the entire rectangle.
6. Now there should be four 18” panels with a line running across horizontally 12” up from the bottom.
7. Mark (T4) the center of each 18” segment along the bottom.
8. Draw (T4)  2 diagonal lines extending from the center mark in opposite directions, so that they form a triangle facing downwards.
9. Repeat this step for all of the four panels.

Step 5: Creating the Armholes

10.3” down from the middle of two alternating panels, draw (T4) and measure (T3) a 6"X12” rectangle going vertically downwards. Cut this shape out using the utility knife (T2).
11. Repeat this on the opposite panel. These shapes are the armholes.

Step 6: Slot

1. 2” in from the two opposite panels, measure (T3) an 18” line.
2. Cut this line using utility knife (T2) so that the line can be the slot.
3. Repeat on the opposite panel.

Step 7: Finishing the Body

15. Finally, score, using utility knife (T2) the three vertical lines that divide the panels

Step 8: Creating the Lid

1. Lay out cardboard (S2) and measure (T3), a 30"X18” rectangle. Cut out using utility knife (T2).
2. Measure  (T3) 6” horizontally inward from the each top corner of the rectangle. Mark using pencil (T4).
3. Extend these lines downwards so that the cardboard is divided into 3 sections, the middle one being 18"X18”.
4. Mark (T4), the center of the middle panel, measure (T3) and draw (T4) a 9X9” square around the center point.
5. Cut the square out using the utility knife (T2).
6. Score (T2) the two vertical lines that are 6” in from each side using utility knife.

Step 9: Creating the Slotter Piece

1. Lay out cardboard, place mat (T1) underneath, (S3) and measure (T3) and mark (T4) a 12"X18” rectangle.
2. Cut it out using the utility knife (T2).
3. Score, using utility knife (T2), the rectangle down the middle (9” in from both sides).

Step 10: Creating the Headpiece

1. Lay out cardboard (S4)and measure (T3) and mark (T4) with 40"X12” rectangle. Put the cutting mat (T1) underneath.
2. Measure (T3) along the top vertically and mark with pencil (T4) every 9”. Repeat along the bottom as well. This will divide the rectangle into five sections (4 equal one smaller).
3. Extend the lines vertically downwards and attach to bottom marks; this will leave an extra 4” for the slotted piece.
4. On the 4” slot, measure (T3) two inches down or up from each of the two corners.
5. Cut (T2) the 2” piece off so that the slot now measures 8X4”.

Step 11:

6. Cut with utility knife (T2), on the second panel in from the slot, a 7"X9” rectangle for the face hole.

Step 12: Parts List

P1            1                   Body
P2            1                   Lid
P3            1                   Slotter
P4            1                   Headpiece

Step 13: Final Assembly

1. Fold the body (P1) along the scored lines
2. Insert the slotter (P2) into the designated slots on the Body (P1). This should secure the box.

Step 14: Assembly

3. Attach the lid (P3) by tucking the flaps into the top square of the body (P1).

Step 15: Assembly

4. Finally, slot the headpiece (P4) so it is a rectangle, then insert it into the 9X9” square on top of the lid (P2).

Step 16: Finished Product

5. This completes the assembly of the cardboard buoy.

Step 17: Attached Plan and Procedures