American Girl Felt Minion Costume

Kunin BP July 30th AG Minion Costume Photo 1

We have been Minion crafting like crazy, Minions are everywhere! McKayla my American Girl doll decided to take over the backyard playhouse and decorate Minion style complete with a polka dot walkway and banner.

Here is what you need to make costume and banners:

  • 1 yd cut by the yard Eco-fi Classicfelt™, Yellow
  • 1/2 yd cut by the yard Eco-fi Classicfelt™,  Royal Blue
  • 9” x 12” craft cuts Kunin Eco-fi Prestofelt™, 1 White, 2 Black, 1 yellow
  • 9” x 12” craft cut Kunin Eco-fi Classicfelt™, 1 Black
  • 5” foam ball, Styrofoam Brand Foam
  • 1 yard ribbon or elastic
  • 3 yards Black ribbon
  • 3/8” Black Buttons, 2
  • 1” Bottle caps, 12
  • Beacon Fabri-tac
  • Scissors, paper, chalk, Sharpie fine and medium point marker, knife, ruler, needle and thread
    TIP: A roll of paper towel makes a great stand when working on the costume.


DQ KBP July 30 Photo 2

1.Making the Costume: Cut a 14” by 22” piece of yellow felt and 6” by 32” for skirt.

2.Cut foam ball in half. Press in center. Use as guide to cut a circle from Prestofelt to adhere to bottom of one half ball. Glue ribbon across top of ball or use elastic, try on doll’s head and make any adjustments as needed.

3.With a straight stitch sew across top of one end of blue felt piece, pull stitches to gather piece to fit bottom of yellow piece. Glue to bottom.

DQ KBP July 30 Photo 3

4.Along the top of the yellow piece cut 2” long petal shaped cuts by trimming out narrow sections in between each cut. Begin gluing as shown in photo. 

5.Overlap last petal glued, leave open, this is the back of costume.

DQ KBP July 30 Photo 4

6.Cut a 3” on one end of the black piece of felt and a 5” fringe on the opposite end leaving 1” in the middle.  Tie a 1” strip of blue felt around the piece pulling in the felt to 2” wide, tie into pony tail. Glue to top of head.

DQ KBP July 30 Photo 5

7.Making the Face: Cut a 1”wide strip of black Prestofelt. Peel off backing and press firmly to face. Glue black buttons to center of bottle caps, glue to black felt.

8.Cut two 1” by 12” pieces from white Prestofelt for teeth. Remove adhesive from white teeth strips and fold back on itself. Draw teeth with the fine point Sharpie, trim bottom teeth edge. Place one teeth piece on face to roughly mark mouth position. (Approximately 1” down from eyes and about 3” wide.)

9.The doll’s eyes and nose should be visible through the mouth. Draw a curved shape to mouth to create right size for your doll. Cut out. Glue teeth to inside of both upper and lower lips.

10.To make bow, cut three pieces of yellow felt 2” by 12”, 2” by 7” and 1” by 2”. Glue 12” piece into loop, notch ends of second piece and place under loop. Wrap center around bow and glue. Glue to skirt as shown.

Place costume on doll, tie under chin. Mark for arm holes if desired and cut out a 3” opening.

To make banners cut a 12” strip of felt in both yellow and blue. Mark at 9” along one side. Mark at 4 ½” along opposite side. Draw a line from each 9” mark to the 4 ½” mark. Cut banners apart. Adhere black Prestofelt 1” strips along top of yellow banners. Make black marker center in bottle caps, glue to black strip. Glue banners to ribbon alternating yellow and blue.

If you enjoyed this fun Minion project check out our Pinterest board for more crafty Minion projects.

You can now find an expanded color line of Kunin Eco-fi Classicfelt; Eco-fiPlus™ Premiumfelt and ShaggiChic non-wovens fabrics in cut by the yard at your local Walmart; please inquire as to what is available in your area. Pick up the Yellow and Royal blue to create a Minion of your own!

Thank you for stopping by! Enjoy the movie!