Robot Halloween Costume

SUPPLIES & TOOLS:

• Sewing machine
• Sewing notions
• Iron
• Sewing tape measure
• Cardboard, box for head approx. 9" H x 7 1/2" x 8", 1 panel 1/8" shy of 7 1/2" x 8" to insert into box (stop for top of head), 2 panels 14" H x 17" W (front and back)
• Masking tape, 2" W
• Utility knife and/or X-Acto® knife
• Rotary cutter & cutting board
• Ruler
• Pencil
• Spray Adhesive & spray area
• Quick Grip adhesive
• Silver pre-cut costume fabric, 2yds x 58" W
• White Velcro®, 3/4"x 4"
• 1/2" elastic, approx. 3yds
• Felt, black, 9"x 12", 2 (interior of box) (optional)
• Crafting supplies for decorative details:
• Sticky back craft foam sheets, small pom poms, wiggle eyes (2 pack, 40mm), styrofoam ball (1 @ 2"), 1/4" dowel (2 @ 4"), chenille stems, ribbon spools, recycled small food containers, acrylic paint, palette & artists brushes

DIRECTIONS:

1. On one 7 1/2"x 8" end score the flaps 1/2" from the sides and cut 2 1/2" from sides. Use masking tape to hold 2" area to inside of box with 1/2" area perpendicular to the sides. Cover the score lines with tape. Keep tape to a minimum, the edges will be slightly visible through the fabric layer. Cut a 5" circle from the center of the insert cardboard panel. Tape the panel into the box about 3" up from the folded edges. Adjust as necessary when fitting. Test fit the box onto child's head with a 7 1/2" side in the front. Measure from the center of one side of the box, under the chin and to the center of the other side of the box for the finished length for a chin strap. Tape the box closed.
2. Cover the box with costume fabric: Spray adhesive to cardboard not fabric unless noted. Cut two panels 10 1/2" H x 18 1/2" W. Mark the center, side to side, of the front and back of the box and centers of the 18 1/2" lengths of fabric. Match centers when attaching. Match top edges of fabric with top edges of box. The bottom 1 1/2" edge of fabric will wrap to the inside of the box.
3. Spray glue one panel centered on the front and wrapped around the sides of the box. Cut 45 degree notches up from the bottom edge of fabric toward the corners of the box. The fabric will mitre at the corners when wrapped to the inside of the box. Spray glue in place. Second panel will cover the cut ends of the first panel on the sides of the box. On the WS of second panel mark a line 2" from both short ends. Spray adhesive in the 2" area and fold back fabric to the marked line. Spray glue panel centered on the back and wrapping around the sides of the box. Wrap the bottom edge inside the box same as the first panel.
4. Cut a top panel 11 1/2"x 12". Cut 2" squares out of each corner. On the WS of fabric mark a line 2" from each edge, connecting the center corners of the corner cutouts. Spray adhesive in the 2" area and fold back each edge of fabric to the marked lines. Spray glue onto the fabric panel and press centered on the top of the box wrapping the folded edges down over the sides of the box. Match the corners.
5. Cut and cover the front and back panels: Score and fold the sides of the panels the same as the lower edge of the box. This will make the cardboard panels less likely to be bent when wearing the costume. Mark and score 2" and 2 1/2" in from the sides of the front and back panels. Fold at the score lines keeping the 1/2" area perpendicular to the center of the panel and wrapping the 2" area to touch the back of the panel. Tape in place keeping the tape as consistent as possible. Cut two fabric panels 17" H x 19" W. On the WS of fabric mark registration points for the corners of the cardboard panel, 1 1/2" from the top and bottom edges and 3 1/2" in from the side edges. Apply spray adhesive to the front of one cardboard panel. Flip and press onto the WS of fabric matching corner marks. Immediately lift cardboard and press the fabric flat. Spray adhesive to the WS of the top and bottom edges of fabric and wrap the fabric to the back of the cardboard. Repeat for the sides of fabric. Repeat for the second panel.
6. Make a paper pattern for shoulder and side ties. Mark a center line 13 1/2" L. Taper the sides from 2 1/2" from the center line to 1" from the center line. A final pattern 13 1/2" L x 5" at one end to 2" at the opposite end. Cut 8. Fold in half RST matching long edges. Sew 1/2" SA leaving 2 1/2" end open. Trim corners close to seam. TRSO. Mark 2" up from open end. Sew across the tie at the 2" mark, down both sides towards the open end, across the end and at least one diagonal back to the stitching 2" from the end of the tie. This will provide a solid area to adhere the tie to the cardboard. Attach the stitched area of ties flush to the back of the cardboard front and back panels with Quick Grip adhesive. Set shoulder ties approx. 5" apart centered on the top edge of panel. Set side ties approx. 1" below center on sides of panel.
7. Cut and sew chin straps. Cut two 3 1/2" W x 14" L (may need to be adjusted). Fold RST lengthwise. Sew 1/4" SA leaving one end open. Trim corners close to seam. TRSO. Sew one side of Velcro starting 3/4" from seamed end centered side to side. Repeat for second strap with opposite side of Velcro. Secure Velcro together. Transfer original chin strap measurement, from fitting, centered on strap. Add an additional 2" past marks on either end of strap. Mark and sew 2" at open end same as ties. Attach the stitched area of ties to either side inside box head.
8. Optional: Finish inside of head with felt. Cut one square the same size as inset cardboard and 4 strips to fit inside the sides. Cut a small slit in the center of the square. Spray adhesive to the square and press in place onto the inset cardboard. Immediately cut lines in the felt radiating from the slit out to the edges of the hole in the inset cardboard. Wrap the felt through the hole to the opposite side of cardboard and press to secure. Spray the side panels of felt and secure inside the sides of the box.
9. Measure for arm and leg wraps. Be mindful of any additional clothing that will be worn under the costume. Stich wraps using a zig zag stitch.

1. Upper arm circumference 8 1/2", wrist circumference 5 1/2", L from underarm to wrist 11 1/2".
2. Cut 2 @ 11 1/2" centered, taper to 8 1/2" centered x 14" L. Double fold 8 1/2" edge (wrist) 1/2" then 1/2". Stitch close to fold. On the WS of fabric mark a line 2 1/2" parallel to the 11 1/2" edge (for top elastic hem fold). Mark 1 1/2" down from top edge on sides of wrap. WST lengthwise matching wrist hem and marks 1 1/2" down. Sew 1/4" SA from wrist to mark. Fold back top raw edge 1/2" and stitch. Fold again to 2 1/2" line and sew close to line. This should leave openings in the top hem on the inside of the wrap for elastic. Secure a safety pin to the end of elastic and pull through top hem. Fit arm wrap for length of elastic. Hand stitch ends of elastic together. Finished L 11".

1. Thigh circumference 13 7/8", ankle circumference 7 3/4"x 17" L.
2. Cut 2 @ 18" centered, taper to 11 3/4" centered x 19 1/2" L. Sew hems and sides and insert elastic at top hem same as arm wraps. Finished L 16 1/2".
3. Decorate head and front and back panels with layers of sticky back foam gauges, buttons, gears and face parts. Craft foam can be cut with an X-Acto knife or scissors. Lay out the cut lines on the paper back of the foam. Additional dimension has been added to parts in the image using small containers painted to match, pom poms for rivets and ribbon rolls, painted black, under some of the gears.
4. Use Quick Grip adhesive to secure any dimensional parts to the fabric covered cardboard.
5. Antennae were added to the top of the head. Cut a Styrofoam ball in half. Use spray adhesive to wrap the curved portion of the balls with fabric wrapping about 1/4" under to the flat side of the Styrofoam. Use an X-Acto knife to cut a small hole in the fabric at the center of the top of the balls. Insert a pencil point into the cut hole to start a hole for the dowel. Paint the dowel to match the robot. Place Quick Grip adhesive into the hole and insert the dowel. Let dry. Add a twist of chenille stems between the tops of the antennae and top the dowels with small pom poms.

JOANN HACKS:

• To add dimensional parts, mark the location on the fabric covered cardboard, remove some of the fabric from the area and glue the part to the cardboard. This will ensure a tight bond and the fabric will not be pulled away from the cardboard by the weight of the dimensional part.
• Consider adding a name to the robot front or back panel to personalize.