Assembling the Materials

• You'll find the most important pieces for the Tin Man costume at a discount, hardware or home-improvement store.
  
  For arms and legs, purchase pieces of clothes dryer vents and ask a store employee to cut them about 6 inches longer than each of your child's limbs. Visit the store's auto parts section and get a metal funnel, big enough to rest comfortably on the child's head. Buy a strong-adhering glue, a roll of gray duct tape and, if you don't have one at home, a staple gun with medium-weight staples. Purchase a few pairs of medical gloves for the Tin Man's hands, and a small decorative watering pitcher for the oil can. Buy two or three cans of silver spray paint to color everything.
  
  The store probably has some empty boxes to use as the Tin Man's body.
  
  Cover all the pieces with the spray paint, including the gloves, and allow them to dry thoroughly before assembling.
  
  

Creating the Body

• Leave one end of the box open, to give the child plenty of room to walk comfortably and safely. Cut arm holes out of the sides, and cut a half-circle from each of the top flaps for the head hole. Tape the flaps shut around the child's head after he gets inside it at party time.
  
  

Making Arms and Legs

• Glue the dryer vents to the inside of the box's arm holes, and apply duct tape for added security.
  
  To make the Tin Man's legs, glue the other two dryer vents to the legs of an old pair of shorts that the child can pull on; use large safety pins to fasten them on more securely.
  
  

Face, Hat, Hands and Oil Can

• Paint the child's face with gray makeup to let her blend in with the metallic look of the rest of the costume. Children 5 and younger may be happy without makeup on.
  
  Glue a piece of string or a rubber band to the top of the funnel, to secure the hat under the child's chin.
  
  Have the child pull on the medical gloves, hand her the "oil can," and she's off to see the Wizard.
  
  

Safety and Practical Concerns

• Measure the box so it's not too big for your child; she should be able to move about freely. Allow about 6 inches between her body and the box. You may have to cut down the box to fit her more comfortably.
  
  The younger the child is, the more likely he is to remove the costume at some point. He should therefore wear some regular clothing underneath.
  
  If the child will be outside at night while wearing the costume, add some glow-in-the-dark paint or tape to the back of the funnel hat and the bottom of the body.