How to Sew a Fleece Hat

Here's an easy sewing project that will keep you warm in winter... A fleece hat that converts to ear muffs or a neck gaiter! Customize your own or give variations away to friends for winter holidays and ski trips.


  1. 1
    Measure the head that the hat will fit. You will need the circumference (distance around) and the distance from one earlobe to the other, going over the crown of the head.

    • Add two inches to the earlobe/crown measurements.
    • Add one inch to the circumference measurement.
      Image titled Measuring_575.JPG
  2. 2
    Cut two rectangles of fleece using these measurements. The two rectangles can be any color(s) of your choice.
  3. 3
    Sew each rectangle into a tube by sewing the narrow ends together.
  4. 4
    # Sew the tubes together along one side. Place one seam facing "outward" and the other seam facing "inward" so that the smooth (non seamed) sides face together. Then pin and sew the long edges together.
  5. 5
    Turn the tubes inside out so that now the seams are hidden and your just sewn seam forms the edge of the material.
  6. 6
    Top stitch 1/2 to 3/4" (1.25 to 2 cm) away from the previous seam, forming a casing (tube to slide the shoelace through).
  7. 7
    Turn/roll the remaining "raw" or unsewn edges half an inch (1.25 cm) to the inside and pin them.
  8. 8
    Top stitch the rolled edges together.
  9. 9
    Top stitch an additional seam two inches from the bottom edge.
  10. 10
    Open the seam at the casing.
  11. 11
    Slide a (new) shoelace through. You can use a safety pin or bodkin to help.
  12. 12
    Put both ends of the shoelace through the cord stop.
  13. 13
    Knot them securely together.
  14. 14
    Gather the cording to form a snug, fleece cap.
  15. 15
    Loosen the cord and fold to form ear protection.
  16. 16
    Loosen the strings and slide down over your head to the neck for a toasty neck gaiter.


  • Depending on who you are making this hat for, you can make them even more enjoyable if you buy patterned fleece!
  • Funky shoelaces can make a cute tie for your hat.
  • Embellish with top stitching, fancy needlework, sequins, shapes made of fleece or felt, or fabric paints. The sky is the limit when it comes to personalizing these!
  • These hats make great Christmas or winter birthday gifts. It is perfect for those who love skiing, snowboarding, or tubing.


  • Scissors and needles are sharp. Handle with appropriate care.
  • Not to be worn by children under three. Keep laces, strings, and ties over 6" in length away from small children.

Things You'll Need

  • Half a yard of fleece fabric. May be in contrasting colors.
  • A (preferably new!) shoelace.
  • Cord Stop (spring type)

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