DIY Aviator Hat
It’s getting to be that time of year again, so it’s time to dust off the sewing machine and get to work on Halloween costumes!
Instead of just deciding what the costumes will be this year by myself, I decided to get Sebastian’s input. After a few choices, he said he wanted to be a pilot for Halloween. And I figured I could do that. I could make Aviator Hats.
And what could be cuter than my boys as the Wright brothers. 🙂
We probably won’t be doing much for Halloween this year since we will be traveling just about at that time, so I wanted something simple but still homemade. And these aviator hats totally fit the bill. I was able to knock them out in one day (not accounting for clingy babies), even with my miscalculations and adjustments.
Brown pleather (or leather if you want to go all out)
White fuzzy felt or fleece
2 medium to large pom poms
**All seam allowances are 1/4 of an inch**
Outside of Aviator Hat
Cut the pieces in the brown pleather, cutting down the rectangular piece to make a total of four pieces for the outside, plus two circles for ear decoration.
Sew the two rectangular pieces together. (In all honesty, this happened because the first hat I made was too large for Sebastian so I made it smaller by taking in the middle this way. But in the end, I liked the look of it, so I did it on Elliot’s hat, too.)
Pin the circles to the side pieces. Sew around, but before closing, stuff a pom pom in to give the ear part some fluff. (This part was the most agognizing for me. My machine’s foot did not want to slide over the pleather so it was a lot of pulling and pushing. I have read that maybe putting some clear tape on the bottom of the foot can make it glide a little better, but I didn’t think of doing that until just now.)
Trim the circle to make it look a little nicer.
Then pin the now larger rectangular piece to the two side pieces, right sides together, following the curvature.
Sew and then flip inside out. Put it on your test subject.
Inside of Aviator Hat
Cut the pieces out of the fuzzy felt. (3 pieces)
Pin the rectangular piece to the two side pieces, right sides together, following the curvature.
Sew. And test on head.
Finishing Aviator Hat
Then you combine the outside and the inside.
Fit the outside into the inside so that the right sides are touching each other. (You could also fit the inside into the outside, just make sure the right sides are touching and are, therefore, not showing.)
Pin all the way around.
Sew all the way around except for the front middle section.
Flip to right sides showing.
Cut a rectangle out of the brown pleather. (4 inches by 8 inches for the 2T-3T size, 4 inches by 6.5 inches for the 12 months)
Fold in half and tuck into the gap in the front.
Pin and sew across, making sure to get the bottom gap closed as well.
Then fold the now smaller rectangle up and pin it across the top, folding the corners in, so no raw edges are exposed.
Sew in place.
Admire your work.
Cut two ovals from the clear vinyl, making slits where indicated.
Glue in place with glue gun.
Cut out ovals from brown pleather with center removed. Paint gold if desired. (I didn’t at first, but adding the gold paint helped the goggles stand out from the hat when placed on top.)
Then working in small sections, glue the center-removed oval to the vinyl along the edge.
Then fold the other edge of the brown up, to cup the edge of the vinyl. Glue in place with glue gun, working in small sections.
Cut two long strips of brown pleather and one small section. Sew the small section to the goggle pieces to act as a bridge.
Then sew the long pieces to the opposite ends.
Place goggles on hat and tie in place.
Really admire your work. Good job! 🙂
I hope that was clear, but if you have any questions, please don’t hesitate to ask. I love answering comments!
And don’t forget about our giveaway happening this week.