We used cardboard boxes for the body and head and feet of this robot costume. Dryer vent tubing for the arms and legs. The body, head and feet were covered with silver tape. The antennae was made with a coat hanger and 2 styrofoam balls covered with tape. We decorated the costume with furniture tacks as rivots, battery operated lights, buss fuses and a DC volt meter and miscellaneous nuts and bolts.
The head had a bike helmet underneath for stability. The back was secured with a Velcro strap.