![]() For the head take laundry basket cut purple felt long enough to cover basket then glue over basket. For arms cutout purple felt long enough for person wearing then glue material together. Cut a circle out of the lid and draw a eyeball on then glue to front of screen. Use your duck tape to cover your butter bowl next glue your small screen to the back of the bowl. Cutout a small bit of purple felt long enough to cover the bottom of the teeth for his lip. With white felt cuout the m that gets glued on pocket of bibs and cutout teeth then glue on purple felt. Then glue black felt over purple felt along with two buttons. Cut purple felt and glue on trash can.For the bibs cut black black felt to look like bibs also cut two long stipes and a pocket. Then cutout be sure to make the eye hole big enough for the butter bowl to fit in. Measure the person wearing the costume to where the arm and eye holes should be. Overalls: I suck at sewing so I did all my work with a rotary cutter, spray adhesive, and then wrapped each edge over on itself.I used trash can, laundry basket, butter bowl, colored duck tape, small screen, purple felt ,black felt, white felt, two buttons, purple yarn , and alot of glue sticks. This way you can then wrap the fabric around the edge. Cut all holes (eyes, mouth) before upholstering. If you have a seam or wrinkle.you want it hidden on the side or back. simply wrap the rest of the fabric around the sides, again starting from the front. It will take more and more pull to get them out as you work to the back. KEY ITEM: Stretch the fabric the least amount possible to get out wrinkles as you go. Press the fabric and let it set for a couple minutes as this will form your anchor. Start by spraying a vertical strip of glue on the front of the dome. I used fleece fabric to give some hiding of imperfections while having some stretch to keep wrinkles out. If it is the golfer you can avoid the dome entirely. If you have the flower lei it will hid seams. BEST ADVICE: If you're building this for someone else, try to talk them into a theme that hides as much of the dome as possible to make your life easier. The key to the minion costume is getting the smoothest dome head possible with the least visible seams. Use a good quality spray adhesive for general gluing and hot glue to tack down high stress seams. The straps around the side are strips of 1/2" EVA foam with lots of the furniture nails to look like rivits again. Be careful to not have trapped dirt and clean the acrylic with windex before install. The whole eye assembly is then hot glued into the goggle at the end. Eyelids are made with EVA foam wrapped in the applicable body fabric (fleece) and hot glued to the hoop. Take it slow to keep the paint thin and not impede the ability to see though the spandex. To get the pupils, I found a tube and did short bursts of spray paint to create each circle. When installed the wearer will be able to see out since it is dark in the costume, but those outside will see light reflect off the white hiding the person inside. Then spandex type material was stretched extremely thin over the frame and tacked in place with hot glue. The eye was made by making a hoop from plastic tubing. The lens is crystal clear acrylic plastic. The furniture nails are used to replicate the rivits. The goggles then need to be trimmed to fit the round body of the minion. Then a 4" wide strip was attached to the back. The goggles were made using EVA foam, weather stripping and round topped furniture nails. It will get you the strongest bond possible between the two sections. This glue expands and soaks into both types of foam. Then climb inside and add a healthy amount of gorilla glue around the edge. Once cured, duct tape to the top of the body tube. Make sure there is a band around the outer rim. Once the dome is off, turn it upside down and spray lines of expanding foam inside to make a "subframe" to give rigidity. It makes a HUGE difference in the final finish quality. I recommend you get light weight wall spackle and try to get the dome as smooth as possible with multiple layers of fill/sand/fill/sand. Deflating too fast can cause vacuum and it will crumple the head. Once the dome has dried on the yoga ball, deflate SLOWLY and remove. ![]() I used a 1:5 ratio of water to elmers glue. ![]() Then multiple layers of paper mache were applied. Then plastic wrap was layered on the yoga ball. The dome top was made by inflating a yoga ball to the appropriate diameter to fit the tube. The body of each minion is a tube of 1/2" EVA foam (aka polyethylene foam) with the edge glued using contact cement. ![]()
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