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For Halloween this year, my youngest son decided to be Lightning McQueen from Pixar's "Cars" movie. Here are a few of the details of the costume construction process. First, a picture of the costume: My basic concept was to create a Lightning McQueen car that he could wear around his waist, with straps over his shoulders as support. I decided to build it out of corrugated cardboard, which I hoped would be sturdy, but still reasonably light (and obviously easy to work with). I had an old large box made of double corrugated cardboard which had plenty of material. Using his matchbox-sized car as a model, I sketched out a profile of the body, and cut it out using a jigsaw. I used two sides of the box, one on top of the other to get two identical profile shapes. Additionally, I cut out a flat shape that I folded and glued into the top (cockpit?) of the car.  I cut a hole in that top portion to fit around his waist. Next, I attached the two sides by creating a fr...