Recycle-Bot

Head: From the bottom, punch out the center of 2 standard light bulbs and remove the insides. Take 2, 9-12V bulbs and hot glue them so the 9-12V bulbs are inside the standard bulb and the wires hang out. Disassemble 2 small flashlights and install 2 more of the 9-12V bulbs to light up the eyes. Glue the small bulbs inside flashlight heads so the wires hang out the back. Now, drill and cut holes in the bucket for the nose and top light and screw them in and secure them with hot glue. Then, drill holes for the wires and hot glue the flashlight eyes in place. Be sure that all wires hang inside the bucket. Note: dont cut out the mouth yet.

Body: Mark, and cut holes in a trash can for the head and arms. Leave adequate room for your childs head. (Optional) cut the black plastic corrugated 90 degree pipe elbows so they fit for the shoulders. The arm holes should be 2-3 from the top of the trash can. Cut the arm holes accurately so the shoulders can be snapped in. If not using the plastic pipe elbows, cut the holes to match the 4" flexible dryer vent material. If not using the plastic pipe elbows, cut the holes to match the 4" flexible dryer vent material.

Control panel: Make, find or buy a wooden box that will hold a square, 9 volt battery and small toggle switch. Leave the back of the box open. I drilled some small holes in the front of the box for a few extra small lights, but these are optional. Once youve made and painted the box, mount the toggle switch on the front. You can decorate the control panel with anything you like.
Connect a small piece of light gage wire from the positive battery terminal to one side of the toggle switch. Cut a 4 piece of wire and attach it to the other side of the toggle switch and leave it hanging. Cut another 4 piece of wire and attach it to the negative battery terminal and leave it hanging. If youre installing lights on the control panel, youll need to wire them now.
Use wood screws to mount the control panel on the body. Before you mount the box, drill two small holes for the power wires hang them inside the body.

Assembly: Next youll need to mount the head on the body. I used a few machine screws and nuts, but you can use whatever works with your bucket. Cut pieces of 4 square foam and press them inside the body so they will comfortably support the weight of the costume on your childs shoulders.

Wiring: Connect the 2 wires from each light to the control panel wires. Use short lengths of light gage wire for extensions so everything reaches. Once the wires are connected, test by toggling the switch and if everything works, secure the wires with electrical tape. Bundle and tape all of the loose wire in the back of the costume so they do not get snagged as your child is putting on or removing the costume.

Mouth: Have your child try on the costume and, mark and cut the mouth so it lines up with their eyes so they can see. Note: do not cut the mouth out while your child is wearing the costume. Cover the mouth from the inside with some mesh screen. You may need to spend a little time checking the thickness and shape of the shoulder padding so the mouth (eyes) line up properly.

Legs: Cut the 6 dryer vent material to length and leave a little extra so they are flexible. Connect suspenders or rope to go over your child's shoulders to hold them up. When putting the costume on, the legs go on first.

Arms: The arms are made from 4 dryer vent material attached to the 90 degree plastic elbows. The arms should be put on last by snapping the shoulders into the armholes.