Cardboard Bird Man Costume With Wings
by David Yakos in Craft > Costumes & Cosplay
27129 Views, 50 Favorites, 0 Comments
Cardboard Bird Man Costume With Wings
![IMG_1996.JPG](/proxy/?url=https://content.instructables.com/FN1/ANY8/IUOHZAO1/FN1ANY8IUOHZAO1.jpg&filename=IMG_1996.JPG)
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We made a costume out of cardboard for my son. It has articulating wings and helmet. I was able to make this in about 5 hours since i have a laser cutter and CAD software at my business, www.salient-tech.com
Design and Cutting the Pieces.
![Capture.JPG](/proxy/?url=https://content.instructables.com/FP1/VTMI/IUOHZB3K/FP1VTMIIUOHZB3K.jpg&filename=Capture.JPG)
![IMG_1999.JPG](/proxy/?url=https://content.instructables.com/FGN/XVON/IUOHZAO7/FGNXVONIUOHZAO7.jpg&filename=IMG_1999.JPG)
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![IMG_1948.JPG](/proxy/?url=https://content.instructables.com/F23/AE79/IUOHZAOF/F23AE79IUOHZAOF.jpg&filename=IMG_1948.JPG)
- I drew this up in Solidworks
- measured my son
- picked good places for wing articulation based on his arm length
- designed 3 sizes of feathers just to fill in the main parts
- Cut out the pieces
- you could use a blade.... i happen to have a laser... so that helps.
Building the Wings and Chest Piece
![IMG_1950.JPG](/proxy/?url=https://content.instructables.com/FRC/UWP4/IUOHZAMC/FRCUWP4IUOHZAMC.jpg&filename=IMG_1950.JPG)
![IMG_1951.JPG](/proxy/?url=https://content.instructables.com/FCA/6J3F/IUOHZAMR/FCA6J3FIUOHZAMR.jpg&filename=IMG_1951.JPG)
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![IMG_1959.JPG](/proxy/?url=https://content.instructables.com/FML/DV46/IUOHZANE/FMLDV46IUOHZANE.jpg&filename=IMG_1959.JPG)
- I bolted the wing pieces together
- use large washers so they don't rip cardboard
- super glue or lock tight nuts in place
- Make straps
- I used gorilla tape
- the waist straps use the restickability of the tape
- Layer feathers starting on the bottom
- Wrist straps are large enough to slide hand in and out
- Head hole needs to be big enough for head too
I used industrial strength hot glue, packing tape and gorilla tape
Making the Bird Man Helmet
![IMG_1953.JPG](/proxy/?url=https://content.instructables.com/FO4/T70S/IUOHZAMV/FO4T70SIUOHZAMV.jpg&filename=IMG_1953.JPG)
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![IMG_1981.JPG](/proxy/?url=https://content.instructables.com/F3Y/P83U/IUOHZANT/F3YP83UIUOHZANT.jpg&filename=IMG_1981.JPG)
- Start with helmet straps and build off of that
- Attach beak and eye parts
- layer feather and ear parts
I used industrial strength hot glue, packing tape and gorilla tape
Have Fun!
![IMG_1992.JPG](/proxy/?url=https://content.instructables.com/FFF/GXEK/IUOHZANV/FFFGXEKIUOHZANV.jpg&filename=IMG_1992.JPG)
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- I added a few more feathers
- Make sure everything fits
- Have fun!