Gigantic Grand Goggles - Slotted Construction Cardboard Costume

Creating costumes, whether for Halloween or something else, can be complicated and time and money consuming. These costumes, once made, can also take up a large amount of space. This task of creating a costume that assembles and dissembles easily for convenience and storage became a school project. Because of the marine theme of the school, the costume also had to be marine themed. 

The design brief of this project is to design and create a cardboard costume that assembles using slotted construction. 

The specifications of this project are:
-create a costume that helps to "Go Green"
-costume must assemble and dissemble easily
-costume must be able to be used by middle-school aged children under limited supervision.

The limitations for this project are:
-use only cardboard
-assemble only using slotted construction
-no fasteners, glue, tape, or any other type of adhesive

Materials:
- Cardboard: size of a small TV box. used for parts 1, 2, & 3

Tools and Equipment:
- Cutting mat: used to cut cardboard on to prevent damage to surfaces.
- Utility knofe:used to cut parts out of cardboard.
- Ruler: used to measure correct dimensions.
- Pencil: used to draw shapes of parts onto cardboard.

Parts List:
  Item - Quantity - Part Name
                                                      P1 - 2 - Arm
                                                      P2 - 1 - Lens
                                                      P3 - 1 - Body

Step 1: Part 1: Arms

1. Measure a 27.5” x 2.5” rectangle onto cardboard using ruler.
2. Draw rectangle onto cardboard using pencil. (See second image below)
3. Cut rectangle out of cardboard using utility knife on cutting mat. (See third image below)
4. Cut a 1.25” deep by .0625” thick slot into cardboard 2.5” from left edge using utility knife. (See forth image below)
5. Cut a 1.25” deep by .0625” thick slot into cardboard 1” from right edge using utility knife. (See fifth image below)
6. Fold cardboard 16.25” from left edge.
7. Repeat.
8. Paint both sides of cardboard if desired.

Step 2: Part 2: Lens

1. Draw organic shape as per orthographic drawing (see second image below for orthographic drawing) onto cardboard using pencil. (See third image below)
2. Cut shape out of cardboard using utility knife on cutting mat. (See forth image below)
3. Fold tabs of cardboard in locations as per orthographic drawing(see second image below for orthographic drawing). (See fifth image below)
4. Paint both sides of cardboard if desired.

Step 3: Part 3: Body

1. Draw orthographic shape as per orthographic drawing (see second image below for orthographic drawing) onto cardboard using pencil.
2. Cut shape out of cardboard using utility knife on cutting mat. (See first image below)
3. Cut slots into cardboard in locations as per orthographic drawing (see second image below for orthographic drawing) using utility knife. (See third image below)
4. Paint both sides of cardboard if desired.

Step 4: Assembly

Parts List:
                                           Item - Quantity - Part Name
                                                      P1 - 2 - Arm
                                                      P2 - 1 - Lens
                                                      P3 - 1 - Body

1. Insert tabs of lens (P2) into correct slots of the body (P3). (See third and forth images below)
2. Slide arms (P1) into body (P3) in correct slots. (See fifth, sixth, seventh, and eighth images below)
3. Cross arms (P1) over each other and slide slots together. (See the ninth and tenth images below)

For a complete, more detailed, printable version, see the attached document below.