My 2 boys are 6 and 8 and they love transformers. I got them hooked on g1 at an early age. And I'll admit I'm living vicariously thought them now because I am building a transformer costume that can actually transform. First we had to figured out who to be. I personally wanted to create something that hasn't been done yet. Luckily last year I got my boys the entire devastator set and they think that they are awesome. So I had to sketch up all of them to see which ones would work best as a costume. We ended up going with Mixmaster and Longhaul.
I've never done anything like this, so I have been searching the net for examples and using my artist/animation background to come up with a working costume. I created a cardboard test where we kept making changes until it sized up right. Once I completed the test part I would use plastic board to build the final. In a perfect world you would use or see duct tape. But I'm on a time crunch so hot glue and DT are my friend.
I've been working on this for a while, but most of the supplies finally arrived so I'm now in high gear to get both costumes done. I've posted several photos on my deviantart page.
First test animation to make sure this could work!
Next I created a prototype of the main parts and modified them til they fit right.
Now that I had good fitting test parts, I re-created them using light plastic colored sheets.
Making sure the final one fits.
I also created the barrel using large construction paper wrapped around foam wheels and small stick framing that I got at Hobby Lobby.