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Minion Costume


posted: 10/23/13

This post may contain affiliate links. Please read my disclosure policy
This post may contain affiliate links. Please read my disclosure policy

This Minion Costume is so easy to make! The perfect homemade Halloween costume, with simple instructions to sew a Minion hat!

little girl with overalls, yellow shirt, and minion hat, and photo says: minion costume

We are totally guilty of letting our two year old watch Despicable Me 2. And judge us if you will, but I’m just saying that if you heard her crack up every time the Minion walked into the room and yelled  “BEEDO! BEEDO! BEEDO! BEEDO!” you would let her watch it too.

So it was kind of a no brainer that Quinny would be wearing a minion costume for Halloween . . . or a BEEDO as she calls them.

little girl in a minion hat

Minion Costume Supplies

In addition to a yellow shirt and overalls, you will need the supplies to make the Minion Hat. For that you will need:

  • Yellow fleece
  • Black felt
  • Silver felt
  • White felt
  • Brown felt
  • Black embroidery thread

Felt is sold by the yard, but it is also sold in 8 by 10 sheets, which is perfect if you need just a small amount. For this project, you will only need a sheet for the black, silver, white, and brown.

little girl in overalls, red shoes, yellow shirt and minion hat

How to Make a Minion Costume

I used one piece of felt cut to the circumference and height of her head, adding on an inch to fold the bottom over and make a finished edge, and another inch on both the length and the width to account for seam allowance. That left me with a piece of yellow felt that was 21 by 8 1/2 inches.

From there, I divided the fleece into four equal peaks, and cut down rounded edges three inches. Here is the ugly picture of how it looked at that point.

Now you are going to cut out all your felt pieces and lay them out on the hat to make sure they are proportional right.

You need to cut:

  • Two black strips (this way the black won’t show through the white eyeball).
  • A sliver circle with the center cut out
  • A white circle that is bigger than the inner part of the silver circle but smaller than the outer part. This will give the appearance of a goggle piece.
  • A brown circle with a small circular chunk cut out

Take a look at my pieces so it makes more sense.

piece of yellow felt cut with four scallop tops and a black strip down the middle

Tips for Finishing it Off

Before you sew your hat, you want to sew on your black strips and your white eyeball, but not the silver hoop. That way you don’t have to worry about your seams  for the hat sewing over the appliquéd eyeball.

Before you sew up your hat, you may want to add some black embroidery thread to the top of the hat (pin it so that it stick down into the hat when flipped inside out). You could also skip this part, minions can be bald, right?

Once you are finished sewing up your hat, add the sliver loop and the brown pupil.

You could always glue it all on with fabric glue, I just thought this might look a little nicer.

Then you just need a yellow long-sleeved shirt (which we didn’t have so we dyed one) and some blue bib overalls.

Little girl wearing a homemade Minion Costume and easy to sew Minion hat

Other Easy Halloween Costumes

We have other easy Halloween costumes too! Tackle one of these simple projects next!

little girl in yellow shirt and overalls with a minion hat

Halloween Treats

Don’t let your little Minions go hungry! Make them some of these amazing Halloween treats to help celebrate.

little girl in overalls wearing a minion hat

Hi! I'm Lisa Longley, and I am committed to giving you simple dinner ideas and recipes that are easy to make; recipes that will fill your home with joy. I am the owner and author of SimpleJoy.com and I'm so glad that you are here.

Reader Interactions


    Have a question? Use the form below to submit your question or comment. I love hearing from you & seeing what you made!

  1. Jessica says

    SO adorable – good work girl!

  2. Dorothy @ Crazy for Crust says

    OMG! SO FREAKING CUTE. Jordan would DIE for that costume. I want one for me too!

  3. Yvonne @ bitter baker says

    I’m a huge stuffing fan too! This looks amazing!

  4. Brianne @ Cupcakes & Kale Chips says

    You have such a little model on your hands! She is too cute, and so is the minion costume!

  5. Minion Costume Lover says

    Really nice work! You make it sound and look simple, quality result and a super cute model to show off this super cute costume! Saw so many cool minion costumes last year I am definitely going to give it a go myself this year! :)

  6. Ildiko says

    Hi! I just love it but I cannot really draw a pattern like this, can you help me?Please!Please!

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5 Secrets to Stress Free Dinners



5 Secrets to Stress Free Dinners