A plastic trash can makes a perfect base for a minion costume from Despicable Me. Brian started with that for his 6-year-old son’s costume and used a rotary cutting tool to cut out the arm holes, mouth hole, and bottom of the trash can. To get the form closer to a minion (not tapered), he wrapped the trash can in foam from a sleeping pad and simply attached it with hot glue. Eventually, he got to the part where he had to paint and dress the minion:
To make the minion come to life, yellow fleece was applied to the foam using spray adhesive. Shapes of fleece were cut close and “dry fit” before being glued down. Careful slits were cut in the dome so folds were not created when wrapping the fleece around the head. The lid of the trash can was done separately from the body, so it could come off for ease getting into the costume.
Acrylic paint and spray painted weaving core was used to detail out the mouth and hair. The hair was stuck into the foam by creating holes with an xacto knife. Overalls from a thrift store were painted and modified to fit around the minion form. Wire pieces act like staples through the overalls and trash can in order to keep the overalls on.
Read more about the build at Coolest Handmade Costumes.