I had a friend go as a much-simplified version of the Tin Man for Halloween a couple years ago without using any actual metal. I don't have a picture, but I found a similar version of what he did on Google:

No one had any trouble guessing what he was, but I'd dress him in something other than jeans. I think if you take the elements that make him the most recognizable (ax, hat, heart) you have plenty of freedom with the body. The hat alone would make him fairly identifiable. Then you could dress him in worn coveralls or a tattered gray/brown suit to really set him apart from the musical.
-------------------------------------------
Ginny Butsch
Community Manager
Educational Theatre Association
Alexandria KY
-------------------------------------------
Original Message:
Sent: 11-01-2014 11:57
From: Scott Piehler
Subject: Tin Woodman costume ideas
This is an image of Nick Chopper, aka The Tin Woodman from Baum's Oz books, as illustrated by John R. Neil. I am directing "Dorothy Meets Alice" for a local community company this winter (Show goes up 1/23-2/1). Looking for ideas for a decent looking way to approximate this. I do NOT want to copy Jack Haley's look in the MGM musical. Thoughts?

-------------------------------------------
Scott Piehler
Drama Director
Lilburn GA
-------------------------------------------