I like homemade carnival disguises. My son wanted a Transformer outfit, he loves the 1986 version of Optimus Prime (Commander in some italian versions).
First we did some research, drew sketches, took measures. The mask proportions were obtained folding a sheet of paper around my son’s head.
Elements of the outfit were drafted with CAD and plotted in full scale. Download here the AutoCAD file (64kB).
Paper was spray glued on cardboard (light for mask, heavy for body and other elements), cut and folded.
Below you can see my son proudly wearing his Commander disguise. Check out this site for amazing paper robots!