Step 1: Planning!! and Supplies
Things you'll need:
12-inch concrete forming tube (Home Depot)
2 12-inch smooth/rounded foam wreaths
White see-through speaker fabric
Sheets of yellow craft foam
Yellow plastic electrical tape (yellow duct tape didn't quite match my foam, the electrical tape was a perfect match)
Cardboard for body
Styrofoam for hats and hands
Kozies (those beer can sleeves)
Step 2: Making the Head
Tape on the foam wreaths, one on each end.
Cut mouth hole. Plan for a large open mouth, so you can see out of it.
Add a cardboard circle to the top to close it off. I then cut an inner circle into the middle of the cardboard top for ventilation (these things get hot). Cut a 2-inch strip of yellow foam and join ends to make a circle. Insert in top hole and tape in place. This creates that nub on top but also keeps the hole open.
Cover mouth hole with speaker fabric.
Draw faces onto yellow craft foam. Attach to tube with spray adhesive. Cover seams and rounded edges with yellow tape. (I originally used yellow duct tape but it didn't match well enough so I went back over with the electrical tape)
**The mouths were about 2 inches from bottom of head. I free handed the faces but you could find printables and blow them up to the correct size.
Step 3: Hats
And I'm not really sure how I made the police hat. That just kind of happened and I didn't get any pictures of the process!
Step 4: Bodies
I wanted to make legs but didn't get that far and it was hard enough for the kids to walk in already.
Step 5: Hands
You may want to add some foam padding to the underside of the piece that rests on the shoulders. These are heavy for kids to wear. My almost 7-yr old was ok but my 4-yr old was not so happy wearing it. We carried his head and hands most of the time.