Do your kids love to dress up or wear Santa hats during the holidays? This Santa Aviator Hat is made from polar fleece and is very easy to make. It’s perfect for dress up play. My kids also love this Dinosaur Tail and these Butterfly Wings for dress up play!
My husband loves airplanes and jets, and all things flying. He’s even taken a few flying lessons; though a pilot’s license is a little beyond our means right now. He is an avid player of flight simulators, and he loves teaching our girls how to fly on his flight simulators. Our 2 year old just LOVES it. She runs in the room yelling, “Fly Daddy’s airplanes! all the time” This is a sponsored post.
Dress Up Costumes
My kids are really into dress up, too. I love to make them dress up costumes that are more than just princess costumes. With the holidays just around the corner, I made this adorable Santa Aviator Hat and matching scarf to wear while flying the airplanes.
Get the Santa Aviator Hat Sewing Pattern
How to make a Santa Aviator Hat and Scarf
This is a really easy tutorial. I used microfleece for this one. You can use regular polar fleece / blizzard fleece. But, I like the feel of microfleece and it’s not as stiff as regular polar fleece.
If you have a serger, you can make most of the hat on your serger. And, the scarf is completely no sew.
Santa Aviator Hat & Scarf
- 1/2 yd white microfleece
- 1/2 yd red microfleece
- 1/4 yd gray microfleece
1. Print the pattern and tape the pieces together as instructed. Then, cut out the pattern pieces.
2. Using the correct size based on head circumference, cut out the fabric with the pattern pieces.
3. Cut a strip of white fleece 1.5 inches x 20 inches to create the pom pom. Use this tutorial to make the pom pom.
4. Now sew the hat side seams together.
5. The brim of the hat has those typical flaps of an aviator hat. To make these, make sure you tape both D Pieces together and cut on the fold. You’ll need 2 of these.
6. Line them up with right sides together and sew around the entire bottom edge with the flaps. Then, flip right side out.
7. Next, we’ll open up the raw edge from each side and line up the two back seams like the above picture, and sew along them. This way, we can fold it, and have a nice continuous edge to attach to the hat like the picture.
8. Fold it so that the raw edges meet, then with right sides together, line up the back seam in the middle of the raw edge of the hat and pin it. Also pin at each side seam and the front middle. Then sew around.
9. Once you have attached it to the hat, fold it down and top stitch along the bottom edges around the flaps, and stitch in the ditch where the hat meets the brim.
10. Now, it’s time to applique. Before sewing the applique, make sure to lay it out exactly how you want it. I laid mine out so that the goggles were partly on the white brim and the red hat. Once satisfied, you can start pinning them or using a spray adhesive to get them to stick before sewing.
11. Cut out 1 nose piece, 2 round gray pieces, and 2 round white pieces (the white should be slightly smaller). Use the chart on the pattern to cut the wrap around piece.
12. You can use pins or a spray adhesive to stick the white rounds onto the gray rounds. Then, sew around them (not on the hat, yet). I use a paper towel behind all of them as a stabilizer. Then set them aside.
13. Now use a pin or spray adhesive to attach the back piece of the goggles around the hat like the pictures. You’ll sew around it like a large rectangle.
14. Now sew the nose piece on the front. I used the paper towel stabilizer under the hat to help.
15. Lastly, place the rounds, and position them with spray adhesive or pins and sew around the gray part. Don’t forget to tear off all the paper towel stabilizer before wearing!
16. Next, attach the pom pom to the tip of the hat with a sewing needle and thread.
17. To make the scarf, just use the chart on the pattern. Once cut, make fringe by cutting a small strip about 1.5 inches deep about every 2 mm on either edge.
Now it’s time to try on your creation! Let me know if you make one!!