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DIY Minecraft Steve Head

He's been played with and worn a lot, so he's a little beat up. 

The head is made from five 8x8 squares of foamboard that I cut with an exacto knife and hot glued together. This was very messy and the foamboard wanted to warp, so I did a little bit of filling in gaps with the hot glue and then painting over it. The black squares of the eyes I cut out for eye-holes. 

After they were glue together, I used a ruler and drew a 1 inch square grid on each side

Inside, I glued a piece of foam to the underside of the top piece to get it to the right height for his eye-holes, and then two pieces of foam where his nose rests. The elastic strap keeps the head from sliding around while he's wearing it.