Sooo, this year i decided to give all my effort for our company costumes party.
After many many ideas, at the final moment ( two weeks a head of the event ) i decided to build a Wall -e costume from scratch !
The build process took A LOT OF TIME !
The costume weights approx 10 Kg and is big in diameter
i didn't imagined the time consuming it was, but eventually it was worth it! and i won the costumes party !!!
I hope you enjoy the building process.
Step 1: Big Carton Box
I mothers washing machine decided to commit suicide , so i had the pleasure in taking the box of the new to be washing machine. :)
With a lot of fitting and cutting i adjusted it to my size
I cannot even illustrate how many cutting i did. and it wasn`t enough since i had to add more angles to the sides of Wall-e ( like his back and his front - it has extra bold add-ons )
So i had to find more card board and attache it
Step 2: Prepare All Sides
Soo .. i have seen a few Wall-E pictures, and also i have a small robot ( toy ) examined all it`s structure and started "molding" all the needed parts.
i assembled them all with paper duck tape at first.
It was a lot of cutting - took hours!
Step 3: Sponge
Some parts of the outer shell I had to fill with sponge - in order to prevent them from collapsing inside
moreover , i added a big thick layer of sponge inside wall-e - where my shoulders are holding the shell - since it is very heavy, i needed something that would give me comfort
Step 4: Rear Parts
The rear parts of wall-e seems like 2 pistons
It is made of wood poles and cardboard
All you need to do is cut it and attach it using cable ties
Don`t forget to paint it in silver + black
Step 5: Front Parts
The front part is the big show - this is the first thing that people look at in the costume.
So, i need to pull something big!
I added this grill in the front + printed this numbers board ( circuit )
Added an old phone (Galaxy s2) - in which i installed 15 videos - each 10 min length that will run in loop- each is a cool visualization.
and of course 12v Battery + LED ( It`s not a costume if you don`t include LED inside it ) :)
Step 6: Apply News Paper to the Structure
In order for the structure to be strong, i had to glue on top of it lots of reading news papers.
sooo, bought a regular white glue ( like children use ) and started the process
Step 7: The Paper Wall-e
Finished with this step and let it dry for an hour or so.
Step 8: Paint It in White
Gives it extra strengthening
Step 9: Prepare Side Wheels #1
The wheels structure was a hard one to create
It was sooo time consuming.
I started to build something, but than it broke apart, and than again I had some idea, and it tear apart.
But finally i was able to build something and got to a state that it was strong enough.
Step 10: Prepare Side Wheels #2
Added additional cardboard on top of it - and strength it with duck tape on the sides
Step 11: Prepare Side Wheels #3
Paint to upper part in silver , and the internal cardboard in black
Than , i took an A4 paper, cut it with a blade and give it a look of tank chain - than you spray it in black to give it a look of cog wheels
Step 12: Prepare Side Wheels #4
Now this was a tricky step, since i need to create an inner structure that would hold the weight of the costume ( since i plan to place it on the floor ) - and it weights approx 10 Kg.
So the base \ wheels structure should be strong.
I got a few wood poles, cut it to the desired size, and attached it to a hard cardboard that i found on the street
I duct taped it all to the wheels shell - used a lot! of duck tape :)
Step 13: Prepare Side Wheels #5
Final touch was adding a printed sample of cog wheels on the sides - to give it a more realistic looks
Step 14: Prepare Wall-e Head
Soo, this was a major step since it took me a few good hours to understand how to connect each cardboard to the other in order to create Wall-e`s head in a perfect way.
I short, you need a bunch of cardboard , paper , duck tape and wood pole to connect to to the body
Step 15: Paint the Body in Yellow
On this step i painted the body in yellow, and i chose the exact color of Wall-e
Than, i spray painted the front in silver
Step 16: Additional Appliances
The side decals are also important since it gives the costume the final looks
Soo, i bought a few colors, some sort of rust color, and another yellow color.
Applied it slowly to the sides and where it needs to be
I also chose to add additional antenna on the back + some old Router board that i had
And also connected some sort of RCA cables to his head
And on the front added some old 1.3 megaPixel camera , 1 fan and an additional electric board + LED of course
Step 17: Add Cardboard on the Hands
I added this addon which i will wrap around my hands
Step 18: Finished !
This was a long fun Instructable !
i hope you enjoyed it
Comments are welcomed