The body and head of this homemade robot boy costume are made from cardboard boxes then wrapped with art paper to make the silver chrome paint more metallic. Head has a construction helmet (we duct taped the helmet in) making the inside fitted to head, eyes are plastic cups painted silver with lights inserted, mouth cut out covered with a black stocking, ears are cardboard cut outs with a blue reflector with coat hangers and a green foam ball tip.
On the body - Meter on the front made from scrapbook paper cut to triangles (to form half circle), gauges are just circles. We used clock hands as the working parts of the gauges and meter. These are attached with brads painted silver.
Lights on the body are LED and chain connected with a push button at left shoulder (you could also just use small reflectors). Meter lights are chain wired and connected to the emergency switch on the back. The battery pack is 6, 9-volt batteries with 20 feet of wire.
The control panel is made with a piece of cardboard and art paper, spray-painted silver and attached to robot with silver painted brads (to mimic rivets) the buttons are reflectors. The words on the robot are all scrapbooking letter stickers.
The arms and legs are silver dryer vent hoses. The arms are connected with silver duct tape on the inside arm holes. Legs are sewn to old shorts with fishing line. Shoes were canvas slip on shoes. We found ours at family dollar and they light up. We spray painted them silver also. If you find white you could just dye them. We looked for silver mittens but could not locate them in TX that would've been a great added feature.
To make this Robot Costume, you will need: 2 boxes, a smaller one and a medium size one depending on size of person dryer tubing battery operated lights spraypaint
For the head we cut out a square shape where his face would appear. We spraypainted both boxes metallic silver. Then for the body we bought some battery operated lights that also played different sounds. We measured and cut out holes all around the edge of the box to fit the string of lights and super glued the lights to hold them in place. All the wires and music box was taped to the inside of the box so they were hidden.
Next we took dryer tubing and measured his arms and legs and safety pined the dryer tubing to his shirt/pants so he looked like the ultimate Robot. We got compliments all night long and what a great job we did and how cute he looked.
This Robot Costume started when my 4 1/2 year old son said, mom I want to be a robot for Halloween. After going to countless costume stores trying to persuade him to change his mind I finally gave in and decided to make him his robot costume.
I started with spray painting and finding boxes that fit him, added on light press lights and sink drains and old wires that I found in the basement supply closet. I added shoe boxes for feet and dryer tubing vents for his arms and legs. I ended up having so much fun making it and he is so proud and cant wait for Halloween.