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How to Make a Robot Suit

by on Jul 5, 2007

Hey Guys!

Have you ever gotten the overwhelming urge to build a freaky robot suit to scare your loved ones but just didn’t know how? Friends, your troubles are over! We have a great tutorial here to create your very own robot suit to terrorize the neighborhood. We’re always looking for cool new projects. If you have an idea of your own, send us your videos! 

For more tips and how to’s, visit our website, Indy Mogul and don’t forget to subscribe to our show on iTunes. If you want to see the complete video, click below.

Shopping List

  1. Football Toy Chest.
    (I saw this at Urban Ore and thought “THAT is my robot torso!” but you could also use a painted cardboard box.)


  2. A medium sized trash can.
    (For the head. It could be any shape. I chose this one because to fit well with the football.)


  3. Two old camera flashes.
    (For eyes. Another lucky find, two matching flashes with blue swing up lenses.)


  4. Heater vent cover.
    (That little piece of metal that is screwed to your wall where air comes out. For a mouth.)


  5. Two old Sega Genesis controllers.
    (Ears of course.)

  6. Big lamp shade.
    (We painted this and it became our robo-midsection.)


  7. A big sheet of cardboard.
    (For the legs. We found this plastic cardboard stuff that was really tough, but regular cardboard would work too.)
  8. Dryer vent hose.
    (The only thing we didn’t buy second hand. Go to any hardware store and buy this classic solution for robot arms.)


  9. Plastic scale.
    (Hard to describe, just this weird plastic piece with a pointed top that I thought would make cool claws…and it did!)


  10. Old “Go-bots” brand 110 camera.
    (A lot of you probably never heard of 110 cameras or the Go-bots, but rest assured the robot NEEDED this item.)


  11. Old video controller.
    (The thing that sits on the robots’ll see.)
  12. Spray paint.
    (I used silver and gold.)

The top half

Because the football looks cooler upside down the first thing we did was cut a hole in the bottom of the football for our actors head and widen the hole at the top for their shoulders. Moving to the trash can, we cut holes for the eyes and mouth. Then we cut holes on either side of the football for our arm hose thingies.

Then taped the grill (teeth) in place behind the mouth, bolted the trash can to the football (head to torso) and duct taped the arms in place.

Two persons fixing suit to robot with tools.
Know to make a robot suit.
DIY project- Robot suit.

Next we cut holes in the chest for both the control panel and the all important “Go-bots” camera. Then, using large amounts of duct tape and hot glue, attached them.

Two man are preparing a robot suit.
"Making a robot suit"

Next comes paint. I used a solid base coat of silver, then a VERY light coat of gold to give it that aged alloy look.

DIY project to make Robot.

Next using hot glue, we attached the rest of the accessories like eyes and 16-bit controller ears.

Two piece of papers having gamepad printed on them.
Old man posing with a Robot.

The lower half

You could almost get away with not having a lower half since you don’t shoot below the waist often, but it’s nice to have the option. So I made my mid-section and legs super simple. An upside down lamp shade and some cardboard taped into tubes. I then cut behind the “knees” of our robot legs to allow them to bend a little. Paint both to match the top half.

A bizarre robot costume to terrify your loved ones.
Man preparing robot suit in the backyard of the house.

The pinchers

Like the football, you probably won’t find these weird little plastic pieces, so just get creative with designing robot hands. Originally I was going to just spray paint some old gloves silver. I basically cut the plastic scale in half, then taped them together to create a basic hinge. Then using hot glue and cardboard I covered the backs of each claw so you couldn’t see the actors hands inside. Finish up with a groovy two tone paint job.

"Steel materials and wires are on the fabric."

You now have all the key components to a vintage style robot.  Mine was pretty uncomfortable to wear. So make sure and buy whoever you get to be inside it a soda…a cold one.

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