Dalu Doll-BIONICLE Inspired Plush Robot Toy.

A small robot doll!

Inspired by the LEGO Bionicle “Dalu” character/set. 

Pattern created by tracing the outlines of the pieces used in the actual Dalu set, then contouring for a softy silhouette. Foam sheets were used for a mock felt test run (Pattern pieces in tutorial photos vary slightly- This was a first-attempt and later refined.)

Small Dalu stands just under 5.5” tall and weighs 3oz.  She is set to swashbuckle with her bubble-bead chargers- But not without the company of her two aquatic allies who rest safely in her sea-snail satchel!

Wholly handsewn except the snail shell, no sewing machine required! 

My total construction time: 29.5 hours

Doll, swords, mask: 16.5 hours.

Doll and mask bead application/embroidery: 7.5 hours.

Sword bead application: 3.5 hours.

Shell construction and beading: 2 hours.

Tools:

Scissors.

Pins and hand sewing needles.

Metal yarn needle and/or strap turner. 

Point turner or stuffing stick.  

Sticky notes and pencil. 

Disappearing/washable ink fabric marker.

One pack of Swedish Fish candy (optional, but rewarding!).

Thread: 

Embroidery floss, 6-strand in various colors.

Polyester sewing machine thread in colors to match your felt.

#69 Bonded Nylon/Tex 70 thread or thick upholstery thread for attaching beads. I used gray and tan. 

Black upholstery thread (for eyes). 

Gold jean/upholstery thread (eye color details).

Fabric needed:

Stiff acrylic nonwoven felt sheets, 1mm thick. I used 4x4” sheets from a multicolor stack found online.

Soft, very thin, interfacing-type lining felt or cotton, preferably in a color that matches your felt sheets (Used to line pieces to prevent poly-fill fibers from leaking through seams). 

Stretch Lycra/silky knit fabric for snail shell. I used knit fabric overlaid with stretch lace. 

Other: 

Poly fill.

BBs or plush weights. I stole some copperhead steel ones from my dad. 

Three small metal, sew-on snaps (For removable mask.)

Assorted beads and sequins. 

Glass fish beads, if Dalu desires friends. 

Clear beading elastic (for holding swords).

Superglue. 

⅛” wide strip of leather (for stabilization of swords).

Terms, stitches, and knots used: 

Hand baseball stitch, single-needle method. 

Hand backstitch. 

Blanket stitch.

Whip stitch.

Ladder stitch.

Tailor’s knot.

Basic sewing machine stitch (Optional, hand-backstitch can be substituted). 

It's a 1-page pattern. I tried to tidy it up a bit in an editor, but it is still rather rough.

*The measurements are in US customary units.

*For personal/non-commercial use only, please.

Apologies for dim tutorial lighting, was done on a lap table tray. 

Note: All body/sword construction stitching is done with double-threaded polyester sewing machine thread. Switching thread colors between each color is recommended for blending effect.

Congrats! Your Dalu is done!