DIY Robot Costume with Duck Tape®

Hi everyone, today I’m sharing a new DIY Robot Costume! I teamed up with Duck Tape^® to create this FUN DIY Halloween costume out of a cardboard box and some Duck Tape.

I love working on DIY Costumes for my for boys I have done many over the years. So I was excited to get the opportunity to work on a new one for my youngest son. It was a fun project to work on together. We loved coming up with ideas together to create this Robot Costume.

So let’s get started and I’ll show you how we made it!

Robot Costume Supplies Needed:

Duck Glitter^® Crafting Tape – Silver, 1.88 in. x 5 yd.
Duck Glitter^® Crafting Tape – Black, 1.88 in. x 5 yd.
Duct Tape – Red
Duct Tape – Black
(4) Craft Adhesive Laminate – Silver Metal, 12 in. x 10 ft.
White Cardstock
Hot Glue Gun
Box Cutter
Silver Pipe Cleaners
Duck^® Brand Kraft Box – Brown, 6 in. x 6 in. x 6 in
Duck^® Brand Kraft Box – Brown, 16 in. x 16 in. x 15 in.
Duck^® Brand Kraft Box – Brown, 12 in. x 12 in. x 10.5 in

Getting Started

Step 1 – Create Your Robot Body

Start off with two 16x16x15 boxes for the body of the robot.

Use your “trusty” box cutter to cut off all four bottom flaps for the top box.

Next flip over and tape off the top part of the box. Make sure to reinforce it as best as you can.

Tape the inside of the box as well.

Finally tape the outside of the top box.

For the second box, cut off all four of the bottom flaps and two of the top flaps.

Step 2 – Combine the two Boxes

Now it’s time to combine the two boxes. I slipped the two flaps into the first box and taped them up, just to help reinforce the robot body a little more.

Then I went around the outside of the boxes and taped them together.

Finally add tape anywhere you can think of on the inside to help keep the structure secure.

Voila, you have your first step done!!

Step 3 – Cover Boxes

Time to cover your box with the metallic laminate! I seriously thought this was the perfect covering for a robot costume. It’s adhesive so I didn’t need to glue it down and didn’t turn out dull like if you spray painted the box silver.

I started on the sides and worked my way around. Then I finished by covering the top. It’s looks seamless!

Step 4 – Cut out Hole for Head

Now we need a spot for the head to go through on the top.

I found a sandwich plate that was the perfect size for the head. Trace out and use your box cutter to cut out!

Step 6 – Cut out Arm Holes

Time to measure out the arm holes. We had our little man try the costume on to see exactly the best place for arm holes.

We needed the hole to be a little smaller then the head hole, so I found a candle we had that was a great size. I traced and cut it out exactly how I did the head.

Step 7 – Cut Costume to Length

The costume was a little too long for our little guy, so we had him try it on. We wanted it to go a little above his knees.

Measure out with a ruler and use your box cutter to cut the extra off.

PERFECT!

Step 8 – Add Details

Now the FUN part! Adding our details to the robot costume!

We looked up some vintage robots on Google and found some great inspiration.

Everything is duck tape besides the white cardstock. I think this part you can get as creative as you want! I used the scrap cardboard to create the red circle and long rectangle at the bottom. I covered both with duck tape.

Looking good so far, right?!!

Step 9 – Create Head

For the head I used a 12×1210.5 box.

I did the head pretty similar to the top of the robot costume box. I tapped the top of the box up. Then I pushed the bottom flaps up inside the box to make the head more secure.

Then I covered the box with the metallic laminate too!

Step 11 – Add Mouth

After we finish adding the metallic laminate it’s time to add the mouth. I had my son put the head on to see where his eyes lined up. Measure out and use the box cutter to cut out mouth.

Once the mouth was cut out I added some screen inside the head.

I cut to size and used some hot glue to keep in place.

Step 12 – Add Eyes

Since my son will be seeing out of the robots mouth, I just made some eyes instead of cutting out eyes into the head.

The glitter is the duck tape glitter and the white part is cardstock. Glue into place.

I think my son is getting excited about his costume!

Step 13- Add Antennas

For the antennas use a box cutter or X-Acto knife and cut a slit into the top. Then gently push the pipe cleaners through. Turn the box over and bend of the ends.

Step 14 – Create Feet

Last by not least lets make some feet cover! This step is optional, but I think it’s a nice touch

We used two 6x6x6 boxes and some of the extra scrap pieces for the shoe covers. My hubby made these covers, he was testing it out and ended up making both while I was out. I didn’t get step pictures.

He taped up the end of the boxes, and extended the front with the scrap pieces.

Then we cut out a hole on top so my son can slip his foot inside. After that we cut out the bottom of the shoe cover.

Finally cover them in the metallic laminate and your finished!! If the boxes wont work, then I think a larger tissue box would work as well, depending on the shoe size.

Finishing Touches

To finish the costume off we ordered a black turtle neck, black pants and silver gloves from Amazon.

As always thanks for stopping by and checking out my latest project. I think this costume will be a hit at truck or treating this year! If you have any questions about the process of making the costume, please don’t hesitate to contact me!

Looking for more DIY Costumes? Check out this Hot Air Balloon Costume I did a couple years ago.