This minion cost about $6 to make. I used white poster board, hot glue, foam, felt, and jean. I made this for my son, he also wanted to be Sonic which you can find on this site too. The Sonic took my awhile, this costume only took a couple days and I let it dry overnight before decorating it. www.JJsHalloweenOutlet.com
Step 1: Step 1 Paper Mache Body
I used plastic chicken wire to make a form for the paper mache head. It would be easier to just use a large balloon. I used about 5 layers and let it dry over night. I then glued and taped white poster board to form the body. I cut the arm holes and let my son try it on. I ended up paper macheing the entire thing because the post board just wasn't strong enough. Next time I will just use cardboard.
Step 2: Step 2 Body
I used a foam noodle to add more structure to the bottom, but if you use cardboard you won't have to do this step at all.
Step 3: Step 3 Yellow Fabric Cover
I cut the hole in front for the eye. The eye and arms are so much easier to cut before you cover them with fabric. I used 1 yard of fabric between the body and the arms. I just the fabric into 4 sections and cut them at an angle to make a point at the top of each piece. Then I sewed them together all the way through and it should make somewhat of a dome shape. pulled the fabric over the body and glued at the bottom edge to secure. I then cut the fabric over the opening for the eye and glued it on the inside.
Step 4: Step 4 Jean Jumper
I used a jean dress for the bibs. The fabric was lighter weight and didn't need much but a trim at the bottom. I also made longer straps and then glued everything down.
Step 5: Step 5 Arms
The arms are really optional. Your child wearing a yellow shirt would be easier. I'm not a great at sewing so I cut a strip a little large than my sons arm (length and width) and then I hand sewed it on. If you do this but the seam of the arm at the bottom :( You can tell in my picture it's at the top lol
Step 6: Step 6 the Face
The eye was a good spot for my 10 year old to see out of. I used my Cricut to cut the circle but you can buy these precut. You can try by hand but it never looks even. I used white foam for the eye and then glued a sheer black fabric on the back. Make sure the white to larger then the eye hole precut on the body. This will cover any imperfections too. I also used foam for the goggle with a black fabric strap. The mouth is black foam with white foam teeth. I cut the tongue out of felt and glued a thin sliver of black in the middle.
Step 7: Step 7 Details
The Minions usually have a logo on the front pocket of their bibs. I put my store logo on it though. The hair is slivers of black felt, hand sewn on. My 6 year old is wearing it in the picture, but it should be just right for my 10 year old. Good Luck!