Ren I feel your pain!!! I made DS a robot party where the kids de orated and then wore their robots. The bodies were staples paper boxes as the bodies and smaller boxes for the head. Dh convinced me that I should "wrap" the boxes instead of painting them, and then slept through me taping and gluing 9 giant boxes and their heads which also had antenae and ears. I had the kids decorate foam as the front panel with little foam bits from michaels. The kids loved it and DS robot survived about 4 months after, and watching his friends walk home in them was great. However, the week before I was a neurotic mess high on craft glue wondering why I was doing this. On the day of I sounded like a visa commercial, priceless! Going to be tough to top for 5!
DeHe
I might steal the wizard station idea!!!