Minion Letter Opener

minion measures 3"

minion measures 3"

Here’s a fun idea for a letter opener, cake server or any tool with a plain metal handle. Follow the step by step instructions for making this simple Minion character from polymer clay. Pop him in the kitchen oven to bake then add details like stitching on the overalls and clear plastic lenses on his goggles. Make this project in any size that will create a convenient handle for your tool.

Before you begin, condition clay. 

IMPORTANT NOTE - Setting numbers vary on clay conditioning machines.  On my machine the thickest setting is 1 and the thinnest is 9.

Directions

step 1 - Roll out yellow clay on the work surface to create a tube. Mist the inside of a 18mm Sculpey Bead Maker. Press the tube into the opening.

step 1 - Roll out yellow clay on the work surface to create a tube. Mist the inside of a 18mm Sculpey Bead Maker. Press the tube into the opening.

step 2 - Slice across the top to remove excess clay and create a level surface.

step 2 - Slice across the top to remove excess clay and create a level surface.

step 3 - Slice off the clay ends even with the plastic edge.  Create a second half tube.

step 3 - Slice off the clay ends even with the plastic edge.  Create a second half tube.

step 4 - Place the metal handle between the two clay pieces and press them together. Blend the edges together. Mold and smooth the top edge into the shape of the Minion’s head.

step 4 - Place the metal handle between the two clay pieces and press them together. Blend the edges together. Mold and smooth the top edge into the shape of the Minion’s head.

step 5 - Roll a thin piece of silver clay on the work surface. Create a figure eight to act as the goggles.

step 5 - Roll a thin piece of silver clay on the work surface. Create a figure eight to act as the goggles.

step 6 - Place the goggles on the upper face.

step 6 - Place the goggles on the upper face.

step 7 - Flatten a piece of black clay about 1/8" wide. Connect it to one end of the goggles and wrap it around the head to reach the other side of the goggles. Blend the ends together. Use a blade to create a gash for the mouth.

step 7 - Flatten a piece of black clay about 1/8" wide. Connect it to one end of the goggles and wrap it around the head to reach the other side of the goggles. Blend the ends together. Use a blade to create a gash for the mouth.

step 8 - Pry the gash open slightly and stuff in a thin piece of white clay to the upper edge. Use a thin sculpting tool to mark separate teeth.

step 8 - Pry the gash open slightly and stuff in a thin piece of white clay to the upper edge. Use a thin sculpting tool to mark separate teeth.

step 9 - Mix blue and a tiny bit of black clay for the denim color. Cut two overall pieces that will reach half way around the body. Create indentations for the pockets on the front half.

step 9 - Mix blue and a tiny bit of black clay for the denim color. Cut two overall pieces that will reach half way around the body. Create indentations for the pockets on the front half.

step 10 - Position the pieces on the body with the sides meeting. Trim excess if needed and blend the seams.

step 10 - Position the pieces on the body with the sides meeting. Trim excess if needed and blend the seams.

step 11 - Roll two thin tubes of yellow clay for the arms and bend them at the elbow. Attach tiny globs of black clay to serve as work gloves.

step 11 - Roll two thin tubes of yellow clay for the arms and bend them at the elbow. Attach tiny globs of black clay to serve as work gloves.

step 12 - Attach the arms to the body slightly below the mouth line. Press the gloves to the pocket lines.

step 12 - Attach the arms to the body slightly below the mouth line. Press the gloves to the pocket lines.

step 13 - Use a sculpting tool to round the bottom of the overalls creating a roll.

step 13 - Use a sculpting tool to round the bottom of the overalls creating a roll.

step 14 - Cut thin pieces of the denim for the overall straps. Connect them to the front and back.  Roll four tiny balls of black for the strap buttons. Cut a denim pocket for the front overall bib. Wrap two thin, short pieces of denim clay to the outside edges of the front and back letter opener below the bottom roll to act as pant legs.

step 14 - Cut thin pieces of the denim for the overall straps. Connect them to the front and back.  Roll four tiny balls of black for the strap buttons. Cut a denim pocket for the front overall bib. Wrap two thin, short pieces of denim clay to the outside edges of the front and back letter opener below the bottom roll to act as pant legs.

step 15 - Add black half circles below the pant leg fronts for work boots. On the back add mere black slashes.

step 15 - Add black half circles below the pant leg fronts for work boots. On the back add mere black slashes.

step 16 - Press a sculpting tool into the side and back seams of the overalls for definition.

step 16 - Press a sculpting tool into the side and back seams of the overalls for definition.

step 17 - Lay the letter opener flat on a parchment paper lined baking sheet. Bake in a 275 degree oven for 30 minutes.

step 18 - Print the image of eyes on card stock. Cut them out and drop them into the goggles.  Add a dot of Elmer’s glue to each. Make sure they are centered. Use thin sharp scissors to cut round circles from clear rigid plastic for the goggle lenses. Use a toothpick to apply E6000 to the very edge of the circles.  Press them carefully onto the edge of the goggle rims.

step 18 - Print the image of eyes on card stock. Cut them out and drop them into the goggles.  Add a dot of Elmer’s glue to each. Make sure they are centered. Use thin sharp scissors to cut round circles from clear rigid plastic for the goggle lenses. Use a toothpick to apply E6000 to the very edge of the circles.  Press them carefully onto the edge of the goggle rims.

step 19 - Add final details.  With a dark orange Sharpie, draw small dashes along all edges of the overalls to represent stitching. With a black marker draw a logo on the bib pocket and a few hairs on the head. Use the black marker to darken the inside of the mouth below the teeth to give the opening depth.


Supplies

At Amazon

  •  Premo Clay - Silver, White, Black, Cadium Yellow, Blue
  •  Sculpey Clay conditioning machine
  •  Sculpey Super Slicer blade set
  •  Sculpey Acrylic Roller
  •  Sculpey Bead Maker Tool
  •  plain handle letter opener
  •  clay sculpting tools
  •  black and orange Sharpie
  •  Fellowes clear binder covers
  •  Elmers glue
  •  E6000 adhesive

Miscellaneous

  •  parchment paper
  •  card stock

Note:  Look for inexpensive letter openers at Amazon under “Arts & Crafts” and at Dollar Stores.


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