I afforded a little extra fabric to cover the inside edge of where the foam body would be connected. The back being in two pieces due to the entrance/exit to the costume. I first cut out fabric for the front bib of the overalls and two halves of that for the back part of the overall bib. I used approximately 1 1/2 yards of stretchy jeans fabric to make the overalls for the minion. Iris’ were hot glued into the appropriate place. I put a coat of mode podge over these to be sure that if it happened to rain the night of Halloween, that they would not run. I used markers to give more color to the iris and a permanent black marker to fill in a smaller black circle for the pupil. I used a small circle of each green and brown thin foam paper for the iris’. More extra foam was cut fit into the silver cardboard paper goggle form, for the whites of the eyes. I used hot glue to join these to pieces together at their edges. I used silver cardboard paper to make the outline of the googles and the front sideways “8” shaped piece. I used a paper outline pinned to the foam body to determine if the size was about right before proceeding further. I often used a bowl of the approximate size to trace to make a perfect circle. Once the foam body was dry, the teeth were then hot glued inside the mouth hole.įor the eyes, I once again used a picture from the Internet to gauge the approximate size of the eyes. I used small scissors to cut each tooth to form and then glued the rows of teeth together in a straight line. At this time, I took the foam body outside to spray paint yellow.īetween spray paint coats, I used the extra foam triangles to form individual teeth for the minion mouth. I also added a thin foam piece to wrap around the bottom part of the mouth hole to make a bottom lip. Once all the hole were made, I took some time to trim the foam around the holes to make more uniform since the inside part had the “egg crate” form to it. I then asked my daughter to assist in measuring the placement of armholes on the sides. Once I was happy, I proceeded to trace the paper form onto the foam with a disappearing fabric marker and cut It out. I made a paper form of the hole and pinned it onto the costume to eyeball if it appeared to be the right size. From the I got took measurements from the picture to gauge the size of the mouth. Using pictures of King Bob from the Internet, I chose a similar facial feature that would work so that my daughter would be able to see through the mouth hole of the costume. The back seam of the foam body I left pinned together for the time being as my intentions for entering in/exiting the costumes would be through there. I used a thin foam paper circle that I cut to cover the hole that was there. They also did not all reach the center of he minion head once glue together. As I was glueing, I realized that I need to add foam into some of the empty spaces to keep the circular shape more uniform. Once this was done, i hot glued all the triangles together to help form the curve to the top of the minion head. To create the circular form to the head, I cut 6 inch tall triangles with 3 inch bases across the top. Using my daughter to gauge the circumference of the body, I wrapped the pad around her and cut to size. I settled on using a foam mattress pad for the body. I didi some research on how to best make a minion costume that would match their shape but also not be too restrictive. My daughter decided she wanted to be a minion for Halloween, but she didn’t want to be just any minion, she wanted to be King Bob from the Minion movie.
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