I use PVC when building large costumes. Here are some techniques that you might find useful. This video covers the materials and tools you need and several methods for building structure and moving joints:

How to bend PVC pipe
How to attach pipe and connectors with screws
How to build a connectorbased moving joint (2 types)
How to build a moving joint freehand
How to connect different sizes of PVC pipe

(My first Mechwarrior costume used the "sanded pipe" version of the joints for the landing legs and the canopy!)

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