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It's going to be difficult to get bike specific boots in small sizes but you'll probably find steel toe cap work boots, only problem with that is the poor kid will struggle to walk in them for a while!
I've never done it myself but a friend of mine gets the armour sewn in by his local alterations place. If you open up the liner at a seam you can sew the armour to the inside of the liner. There were some types of armour that came with little poppers that you pressed through the liner to hold them in place.
Overall I'd think quite carefully about the kind of biking I'm going to be doing with a tiny pillion. You might put a lot of effort in just to find that they don't like it as much as you think they will. It's always easier if your pillion understands the risks involved in getting on a bike. I don't take pillions as much as I used to but I've never had young ones on the back, it wouldn't be enjoyable for me.
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Airhead
Thanks. not far off what I had in mind.
What boots to go for then?
Also. do you know of a guide to add armour to a non armoured jacket? I'm relatively handy and trust myself to do it so would like to lean on someones experiences so I don't have to invent everything myself. If someone made and sold finished pockets that I could just stitch in that would be nice...