You want to build this. Yes you do.
Step 1: Gather Your Materials
1) Minecraft image files (linked below)
2) Color printer
3) Print software (free)
5) Measuring tape
6) Spray adhesive
7) Wood glue
9) Utility knife
11) Styrofoam (optional)
12) Pantyhose & Glue gun (optional)
Step 2: Design Options
You will require a number large size cardboard pieces. You can probably go to an electronics or appliance store and ask for their boxes. I was lucky enough to get large recycled boxes from the warehouse at the company i work for but you'll have to find your own cardboard somehow. Depending on the sizes of cardboard you have, there are 2 ways to tackle the design as shown in the images above. For a body part, you can either cut each side with an internal flap as separate pieces or you can cut the entire body part with a single piece of cardboard. It is probably best to do it with a single piece as it will hold together better but this decision will ultimately be based on the size of the cardboard you have. All flaps will be held together with some wood glue and can internally be reinforced with some masking tape. Wide masking tape can also be used on all the outer creases and edges of the box for reinforcement.
Step 3: Torso
Everybody's body is different (except mine. It is the same. what?). This build will require some measurement to custom fit your body. I am 6'1 at 200lbs and have built this to my measurements. You can lay down on a piece of cardboard and measure from the top of your shoulders to just below your waste and base the height of the torso/arms on that. The torso and arms should be the same height and width (length of the arms should be half that of the torso). Dotted lines depicted in the graphics above are score lines. Use your utility knife to cut about half way or just deep enough to allow the cardboard to bend on the crease (don't cut all the way down!).
Once done the torso, you can cut some holes for the arms and head. In my case, i cut a 6 x 10 hole on the bottom of the head/top of the torso. The arms i cut a 6 x 9 hole with a rounded top.
Step 4: Arms
For the arms, you will need to add handles to grip onto when you wear the arm. To do this, do not glue the bottom flap that closes the arm ends just yet. Keep it open so you can add a handle from that end. You can just use a simple strip of cardboard to do this. There is no set width for the strip as it will vary with hand sizes, but just find something that is comfortable for you. To match the torso arm holes, i also did a 6 x 9 cutout with rounded tops.
Step 5: Legs
I added a flap to cover the upper open area of the front of the leg. This looked better cosmetically as well as offered support. I also placed some foam pads (cardboard could also be used) beneath the added flap as well as on the sides as sides and some beneath the back of my ankle.
Step 6: Head
Before you glue the head shut with glue/tape (which will eventually just look like a square box) , you will need to add some internal support for the top of your head so the head can turn as you turn. Because this box will rest on the torso shoulders, your head never actually makes contact with anything inside the box and this is why supports are required. To do this, add a cardboard insert the same dimensions as the box, being sure to add flaps on all 4 sides so you can glue/tape it in place. Cut an oval hole in the center to fit the top of your head. Glue/tape it about half-way in or where you believe it will contact the top part of your head. It should fit like a hat. You can add some foam inserts or additional cardboard to make it more comfortable.
Step 7: Try It On..
If you measured and cut correctly according to your dimensions, this thing should fit just fine. Because the torso and legs have open ends, these can be trimmed down to fit. Any torso alteration would cause the arms to be longer as they were originally designed to have the same height dimensions.
You can also cut a rectangular hole for the mouth.
Step 8: Time to Print
Because each printed side requires multiple papers to span across it, poster software will be required. There are a number of free software titles that allow you to do this. They all typically work the same. Open your picture in the software, choose how many papers you want it to break it down to (make sure it matches the size of your printer paper), turn on or off options like adding overlap or borders and voila!
As well as the files for Steve, I have included the breakdown of the head using some poster software to show how each side is actually broken down into 6 sheets. In my case, i used larger paper to print on so they may not work for you. Just use the source files with the software and you'll be good.
Step 9: Stick With It
Once you've cut down your sheets so only the image is present and no white borders are showing, loosely place them on the box to ensure they are in fact the right size!
If all looks good, just give a good spray of the spray adhesive (i recommend this over glue as it holds better and does not show any grooves or bumps if done right). Make sure you cover all areas of the back of the sheet with spray glue, place each piece of paper onto the body part you are working on (starting with the top left corner might be easier) and work your way down until you are done a side. Now, do this a million times over until you are done each side of each part. You can just re-use some printed sides for some obscure areas like the top of the torso, flaps near the knees, etc. Cut through the arm/torso/head holes and secure the edges with tape (even Scotch tape could work as this part will be invisible to others).
Step 10: Finishing Touches
I cut a thin layer of pantyhose and glued it with hot glue on the inside of the head and again with tape to cover the mouth. This provided a nice finish with good visibility while keeping you hidden inside.
Step 11: Take a Break..
You deserved it.