STYROFOAM™Brand Foam:
Block, 12" x 6" x 1"
Cone, 9" x 4"
Egg, 4"
Other Materials:
Non-woven felt: 36" burgundy, 1/2 yd.; beige, black, 9" x 12" sheet each
Fabrics: 9" x 12" plaid flannel; 8" x 16" burlap or tweed
Fiberfill stuffing
Wavy wool, 6 oz.
Ivory embroidery floss
Jute twine, 16" length
Beige buttons, 1/2", three
Black beads, 6mm, two
Cosmetic blush
Artificial pine spray
Twig, 8" long
Serrated knife
Candle stub or paraffin
Fine-line black permanent marker
Pencil
Ruler
Compass or 4"circle template
Scissors
Embroidery needle
Iron and ironing board
Clothes dryer
Sink
Low-temp glue gun and glue sticks
Thick, white craft glue
Instructions
1. Wax serrated knife with candle stub or paraffin. Cut 1"-thick slice from narrow end of foam egg, creating flat top of head. Use scissors point to slightly hollow out wide end of egg to fit over tip of cone body. Cut boot pattern from foam block.
2. Prepare burgundy felt by soaking in warm water for a few minutes. Squeeze excess water from fabric and place in clothes dryer for about 30 minutes until almost dry. Lay fabric flat to finish drying; shrinkage gives fabric a vintage, felted texture.
3. Clean stray bits of foam from work surface before cutting fabrics. Cut the following pieces from burgundy felt: 12" x 16" coat; 11" square hat; 2-1/2" x 16" coat trim. Cut pattern pieces as indicated. In addition, cut 4" x 9" rectangle from beige felt for head.
4. Trace foam boots onto black felt; cut out 1/2" larger all around to cover top of boots. Cut two 1" x 9" strips from black felt to cover boot sides.
5. Center and glue top boot piece over foam boots; glue excess felt to foam sides. Clip felt at center. Glue bottom boot piece to foam. Beginning at center front where boots meet, glue felt strips to foam sides; trim excess as needed. Glue body to boots, aligning back edge of cone with back edge of boots.
6. Place plaid pants strip right side down on ironing board. Press 1/2" hem along long edge. Turn pants over. Cuff pressed edge up 1-1/2"; press. Place pants around bottom of body, overlapping and gluing edges at back; trim excess. Use knife edge to press seam line into foam at center front of pants.
7. Glue head to top of body. Evenly wrap beige felt piece cut in Step 3 around head, overlapping edges at back; glue felt edges to secure. Felt should meet cone under head; trim excess. Glue wavy wool to head for hair, mustache and beard.
8. Refer to photo to create face. Use scissors point to make two holes for eyes in foam, 3/8" apart. Glue beads in place, pushing beads firmly into holes. Glue nose to face. Use fingertip to apply blush to cheeks. Glue tiny pieces of wool above eyes for eyebrows.
9. To make coat, double fold coat felt to measure 6" x 8". Refer to diagram to cut 3" x 5" rectangle from bottom outside corners; discard scraps. Cut through one layer of center fold only to create front coat opening. Clip 1/2" from center along each top fold to create neck opening.
10. Place coat on work surface, right sides together and underarms aligned. Glue underarm seams; let dry. Clip corners and turn coat right side out.
11. Use three strands ivory floss to stitch along top of pocket. Glue pocket to front of coat.
12. Glue coat trim strip in half to measure 1-1/4" wide; cut in half. Glue trim to each side of front opening; trim excess. Sew buttons to coat trim as shown. Place coat on Santa, gluing felt around top of body and overlapping front edges slightly.
13. Glue mitten halves together along outside edges, leaving tops open; stuff lightly with fiberfill. Turn up coat sleeves 1''; glue to secure. Stuff sleeves lightly with fiberfill. Glue mittens into ends of sleeves.
14. Fold felt hat piece in half; cut diagonally from one outside corner to fold and discard scraps. With right sides facing, glue hat together along diagonal; let dry. Turn hat right side out and stuff lightly with fiberfill. Turn up brim 1".
15. Cut 4" circle from beige felt for hat pom pom. Sew gathering stitch around outside of circle. Place small amount fiberfill in center of felt and pull threads to gather, leaving very small opening; clip ends. Glue pom pom over tip of hat and hat to head.
16. Fold burlap in half, right sides together. Glue fabric along side and bottom edges, leaving top open. Turn right side out. Fold and glue top edge under 1/2". Stuff bag lightly with fiberfill. Tie jute around bag to close. Glue bag to Santa's shoulder. Glue one mitten to bag as shown; glue twig walking stick to other mitten.
