So my first Instructable is for my 5 yr old autistic son's Wall-E costume. We could not talk him into anything easier, so what's a dad to do?
I have about $15 dollars wrapped up in this project as I had the majority of the materials laying around. The most difficult part of this was the timing. It turned out that I had 3 days to complete this and he was very anxious... constantly to try it on.
Here's the list of what he's made of:
1- 4x8 sheet of 3/4" pink foam board
1- roll of 5/8" foam caulk
2- Mini CDs
nylon shower surround
Hot glue and gun
rattle can black, yellow, nickel, brown, blue (For eyes)
acrylic black, yellow, red, white, silver, brown
Kills latex paint
Step 1: The Build
I started off by measuring my son across his shoulders as I wanted him to have plenty of room to move. (Autistic children sometimes will freak if they feel trapped.
Once I had my initial measurements I cut the nylon and created tabs so I could rivet them all together. From there I cut the foam and attached it to the nylon with Gorilla Glue and hot glue (to hold it till the Gorilla dried). Once I had it all together I started going at it with the Dremel. The only part of the build part of the build that wasn't free handed was where I masked off with frog tape for the black and nickel spray.
The eyes are mini CDs and the head is hand shaped metal flashing. If I had more time I would have liked to get out my airbrush and do a better job with details, but this was pretty last minute.
I think you can get a good idea of the build from the pics, but remember: prior to spraying lacquer on foam you have to coat it so the acetone won't "eat" it.
Though I didn't have the details as I would have liked them, my son and pretty much everyone else thought it was wicked cute.
One thing I forget: I painted a baseball cap gray and screwed the "Head" to it... "Hind sight is always 20/20, but looking back now it's still a little fuzzy..."