/cgl/ - Cosplay & EGL

This isn't for Halloween, so I have tons of time to actually work on this.

I wanted to make a replica of the cardboard box from MGSV, with the Idol Paz posters on the side and the top of the box. To be clear, I won't be dressed up as Snake under the box, the box itself would be the costume (plus boots and suitable pants, since they'll be seen).

I want to actually be able to "transform" the box into a standing and crouching position like in the game. I figure the best way to do this, without having the entire thing fall apart on me is to use Velcro "locks" on the inside flaps where they're needed, so that the back doesn't fall apart when I'm trying to life the front, etc. Does this sound feasible? I've already scaled myself to Snake's height from screenshots, and found when put together, the dimensions would be (4)x(3)x(2+2/3) ft. I made a small paper model, with all the edges permanently connected where they should be, and open where it needs to move, and where all the Velcro should go if I stick with that idea.

I feel like it would work, but of course, I've never tried, and I have next to no experience with prop making. Also, what material should I make it out of? Cardboard is the obvious and cheap choice, but would I get better results, or something less likely to break by using foam or something?