How to Create a Slotted Construction Cardboard Shark

This shark costume consists of strictly cardboard.  It is designed using slotted contruction, to save space.  Slotted construction also helps the environment because it allows the costume to be made entirely out of cardboard, eliminating the need for harmful adhesives.  All cutting should be done with a cutting mat under the piece you are cutting.

Design brief
- design and produce a flat pack or slotted design cardboard costume for middle school aged children

Specs
-flat pack/ slotted design
-must fit middle school agred children
-constructed using only cardboard

limits
-flat pack/ slotted design
-must fit middle school agred children
-constructed using only cardboard
-no adhesives permitted
-child must be able to move



Supply List:
Cardboard  
Three Pieces 9"x 9"
Two pieces 1"x 5"
One piece 38"x31" (Some Television, fridge or moving boxes are possible examples of where one might find this size cardboard.)
One piece 14"x 15"
One piece 13"x 15"
One piece 9"x 9"
One piece 1"x 5"

Tools and Equipment list:
Cutting mat
Utility knife
Ruler
Pencil

Step 1: P1: Body

1.  Using a pencil, draw two ovals each 31" tall and 17" wide with a 4" gap between each oval.   
2.  Using a ruler, on both ovals, measure up and down 6" from the middle and mark each spot.
3.  Using a pencil, draw a horizontal line, connecting the opposite top marks and bottom marks together.
4.  Using a ruler, measure 2' down from one end on one oval.
5.  Using a pencil, draw a 2" vertical line along the ruler.
6.  On the other end, on both ovals, using a ruler, measure down 3".
7.  Using a pencil, draw a 2" horizontal line where the 3" vertical line ends.
8.  Using a ruler, measure out vertically, 0.5" from the outsides of the body. 
9.  Using a pencil, draw a line alongside the ruler.
10.  Using a utility knife, cut out the ovals and along the lines connectiong the ovals, but do not cut between the connecting lines.
11.  Using a utility knife, score the inside of the body.  This will allow the body to curve, therefore looking more like an actual shark. 

Step 2: P2: Pectoral Fins

1.  Using a pencil, draw two (separate) triangles that are 8" tall and 9" wide, with a 2" wide by 1" long rectangle , on the middle of each triangle's side that is 9" long. 
2.  Using a utility knife,  cut out the pectoral fins.
3.  For one pectoral fin, using a utility knife cut out a 0.25" wide by 0.5" deep in the rectangle. 

Step 3: P3: Connector Pieces

1.  Using a ruler and a pencil, draw a 1" by 5" rectangle.
2.  Using a ruler and a pencil, draw two 0.5" lines.  Each line should be on one of long edge on the rectangle and each should be 0.5" from the edge.
3.  Using a ruler and a pencil, draw a 0.5" line in the middle on the other long edge of the rectangle.
4.  Using a utility knife, cut along all drawn lines.

Step 4: P4: Head

1.  Using a ruler and a pencil, draw an oval that is 14"x 11".  (An oval template or a guide would be useful in this situation, but are not necessary.)
2.  Using a ruler and a pencil, draw a 2"x 1" rectangle on each thinner side of the oval.
3.  Using a ruler and a pencil, draw a circle with a 9" diameter.  (A circle template or a guide would be useful in this situatuation, but neither are necessary.) 
4.  Using a utility knife, make cuts on all drawn lines.  However, do not cut the parts of the oval that are inside the two rectangular tabs.

Step 5: P5: Caudal Fin

1.  Using a ruler and a pencil, draw one triangle that is 4"x 12"x 9".  Then, draw another triangle that overlaps the first.  The second triangle should be 5"x 11"x 8". 
2.  Using a ruler and a pencil, draw a 3"x 7" rectangle.  The rectangle should only protrude past the two triangles by about 2", so there should be about 3" of overlap between the rectangle and the triangles.
3.  Using a ruler and a pencil, draw a line that is 1" in the middle of the front of the rectangle. 
4.  Using a utility knife, cut along all drawn lines.

Step 6: P6: Dorsal Fin

1. Using a pencil, draw two (separate) triangles that are 8" tall and 9" wide, with a 2" wide by 1" long rectangle , on the middle of each triangle's side that is 9" long.
2. Using a utility knife, cut out the pectoral fins.

Step 7: Assembly

Part List
P1  Body
P2  Pectoral Fins
P3  Connector Pieces
P4  Headpiece
P5  Caudal Fin
P6  Dorsal Fin

1. Fold P1 where the two ovals meet the centerpiece.
2. Insert P3 into P1.
3. Insert one P2 into P3 and one P2 into P1.
3. Insert P4 into P1.
4. Insert P5 into P1.
5. Insert P6 into P1.