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DIY Minions Hat

November 3, 2013 /

minion hat
With the recent flu attack and falling sick, I have almost forgotten that I have promised my son to make him a hat for his school’s hat party on the next day, all hats made by parents will be eligible to enter into the hat contest.

At the very last minute and with very limited resources that I have found in my stashes, I am pleased to finally be able to keep my word to make him a Minions inspired Hat. The hat had been retained by the school for the contest and hope we will hear some good news soon.

minions hat

It took me half a day to design and make it, now with all the templates I prepared for you, I would say you will only need an hour or so to complete it. Simple and quick craft for the Despicable Me Minions fans!

After completing the hat, I still have some ample time to make a Minions Goggle Mask for my son to wear as a bonus.

Look at my son, he is so happy with the hat and would pose any style in front of the camera. We took all these pictures the next morning just before sending him to school for the hat party. It is difficult for me to decide which pictures to share, so I made a contact sheet out of them. To view a bigger pictures of some of them, please click the above album to browse through.

20 faces of minions hat

It is time to plan and make for Christmas crafts and baking, hope everything goes smoothly and I promise to share as many as I could.

cardboard minions hat

Minions Hat

Make: 1
Materials & Tools:
1. Minions Hat Templates
2. Colored Corrugated Cardboard, yellow (22″ x 22″)
3. Colored Corrugated Cardboard, silver-grey, 3″ x 6″
4. Cardboard, white 3″ x 5″
5. Paper, black, 18″ x 1/2″
6. Acrylic paint, brown, black and white
7. Fine tip brushes
8. Bone folder
9. Awl tool
10. Mod Podge or white PV craft glue
11. Foam brush
12. Scissors
13. Black yarns
14. Math compass and ruler

Minions Goggle Mask

Make: 1
Materials & Tools:
1. Synthetic Felt, 2mm thickness, black, 3″ x 9″
2. White color pencil
3. Round Cord Elastic Band 1/16″, 1 yard (you can buy from hair accessories section, or hereelastic band)
4. Quick-dry all-purpose adhesive (clear color), for example, UHUUHU

minions-hat-templatesDownload and print the minions’ hat and mask templates, or you can draw them directly on the cardboard. After download, open it in Adobe Reader and print on paper. Don’t print from browser, the size might not in correct scale.

materialsDraw the hat templates directly on the yellow corrugated cardboard, trace or draw the Minions goggle and eyes on respective cardboard. Cut all templates with scissors.
You may trim the Minions eye a little different like I did.

paint minions eyes 1Color the irises of the eyes in dark brown acrylic paint.

paint minions eyes 2Paint the pupils and outline the eyes with black acrylic paint.

paint minions eyes 3Highlight the eyes with some whites acrylic paint.

edge foldingPress the folding lines of the hat top and brim with the bone folder to make them easier to fold smoothly.

apply glueApply glue to the glue seam allowance of the right side of the brim.

attach brimAttach the band to the brim and make sure they glued well to each other.

attach hat topFlip the hat upside down and glue the top to the band in the same manner.

basic hatA finished basic yellow cardboard hat. It is ready to be decorated into Minions hat.

glue goggle strapGlue black strap to the center of the hatband.

assemble eyesAssemble and glue the Minions’ eyes and goggles together, then glue them on the hat. Hold them with your hand until they adhered well on the curve of the hatband.

minions hair 1Tie a bunch of black yarns together at the center.
Poke the same number of holes on the hat top as the number of yarns you have tied.

minions hair 4Apply a small amount of craft glue to the end of the yarn, twist it to make it pointy and stiff.
Insert yarn end from inside of the hat through the hole.

minions hair 3Apply a generous amount of glue to the knot of the yarn inside the hat to fix it there.

minions hair 5Trim the hair to about 1″ – 1 1/2″ long.
Set it aside for at least 2 hours before wearing it.
I also added a smile on the brim the next day with a black permanent marker.

DIY-minions-goggle-mask-1Trace and cut goggles template out from felt.
Fold 1/2″ from the sideband, glue the edge with all-purpose quick dry adhesive to make a pocket at each side. Clamp them with clothes clips for about 30 minutes for a permanent bond.
Measure and cut the correct length of an elastic cord according to the wearer size, insert the elastic band through the pocket of the goggle band, tie the ends and hide into one of the pockets.

cardboard minions hat

diy minions goggle mask


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Creative Hats Ideas · Craftwhack

Friday 4th of February 2022

[…] Get the template from […]


Tuesday 15th of August 2017

Thank you very much for good idea of the Minions Hat!

Cindy deRosier

Wednesday 1st of July 2015

I'm the Editorial Assistant for Fun Family Crafts and I wanted to let you know that we have featured your Minion hat! You can see it here:

If you have other kid-friendly craft tutorials, we'd love it if you would submit them. If you would like to display a featured button on your site, you can grab one from the right side bar of your post above. Thanks for an awesome project idea!

Craft Passion

Friday 3rd of July 2015

Thank you, Cindy, for linking the Minion Hat in your great site :)