12 Hour Wall-E Costume

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
duct tape
pop rivets
Metal sheeting
2- Mini CDs
nylon shower surround
Gorilla Glue
Hot glue and gun
rattle can black, yellow, nickel, brown, blue (For eyes)
acrylic black, yellow, red, white, silver, brown
Kills latex paint
Frog tape

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..."