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
13. Black yarns
14. Math compass and ruler
Minions Goggle Mask
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 here)
4. Quick dry all purpose adhesive (clear color), for example, UHU
Download 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.
Draw 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.
Color the irises of the eyes in dark brown acrylic paint.
Paint the pupils and outline the eyes with black acrylic paint.
Highlight the eyes with some whites acrylic paint.
Press the folding lines of the hat top and brim with bone folder to make them easier to fold smoothly.
Apply glue to the glue seam allowance of the right side of the brim.
Attach the band to the brim and make sure they glued well to each other.
Flip the hat upside down and glue the top to the band with the same manner.
A finished basic yellow cardboard hat. It is ready to be decorated into Minions hat.
Glue black strap to the center of the hat band.
Assemble 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 hat band.
Tie 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.
Apply 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.
Apply generous amount of glue to he knot of the yarn inside the hat to fix it there.
Trim 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 black permanent marker.
Trace and cut goggle template out from felt.
Fold 1/2″ from the side band, 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 permanent bond.
Measure and cut the correct length of 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.