In 2004 I ended up having some time on my hands about three days before a big Halloween party. I did what anyone would do, I built robot costume out of cardboard boxes and dryer hose.
Sorry the photos aren’t better, for some weird reason I had set my camera on super low file size. I wish I had taken more shots of the build but I was trying to meet a deadline.
The whole thing was bonded together with tape (clear packing and gaffers), hot glue, and lots of brass paper brads. I used dryer hose for the arms and as it had to fit up to my shoulders I clipped the wires in them for about eight inches on the inside at the tops and covered them with some gaffers tape so I wouldn’t get poked. I tied them together with two short sections of rope,one across my chest and the other on my back. This kept the sleeves from coming off and falling to my wrists. I added some cardboard cuffs to hide the claw interface.
The claws were made from heavy tag board and regular corrugated cardboard. I wore them like mittens and my fingers ran through some cardboard loops on the inside so I could operate them. The hinges were paper brads.
I wanted rivets on my robot so I used about two boxes of brads all over the thing. They worked real well as surface detail and as actual mechanical reinforcements. I ran tape on the backside to avoid the sharp ends.
The name badge was simply an old LED chaser badge that I had built in the late 80′s. I mounted it to the costume with hot glue. I added some details like the chest logo and the static bag eyes after I slathered on a few coats of this water based gray paint I found at Home Depot.
The costume was a success, after the party I went trick or treating with my kids and I can’t tell you how many comments I got from kids and parents alike.
For more photos of my costume, got have a look at the photos on Flickr.
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