Even if you don't have a ton of sewing experience, this cozy fleece hat is easy to make. It's also fun to wear and has mittens attached. What child wouldn't adore a cute penguin sitting on their head, keeping them oh so warm!
Prepare the Pattern and Cut the Fleece
Print all pattern pages at 100% and cut out the pieces. Tape the pieces together as necessary, along dotted lines. From a folded piece of white fleece, cut out (2), Mittens (2) and Hat Body (4). Cut out one white Interior Hat Band on the fold as indicated. Cut one white Face (1). From a folded piece of black fleece, cut the Hat Body (4) and Wings (2). Cut one black Exterior Hat Band. From the accent color, cut a Accent Hat Band (1) and a rectangle about 3 inches by 12 inches for the bow. Finally, cut an orange Beak and two black Eyes.
Stitch Together the Hat Body
Pin two black Hat Bodies with right sides together. Using a 1/4 inch seam, stitch from the base to the tip on one side.
Use a narrow zig-zag stitch to sew all seams to maintain the stretch of the fabric.
Stitch together the second set of the black Hat Bodies.
Pin and stitch these two sections together on both sides to form the basic Hat Body.
Following the same procedure and sew the white Hat Body pieces together.
Sew the Wings
On each Mitten piece, fold down 1/2 inch hem and stitch close to the edge.
With right sides up, place a white Mitten on top of the white Wing. Top this with a black Wing, right side down, Stitch from the top right of the Wing, around the Mitten and back up to the top left side.
Turn each Wing inside out and press lightly with a slightly warm iron.
Place the Wings with the straight, white side facing the front and centered on the side seams of the Hat Body assembly. Pin and stitch in place.
Attach the Hat Band
With right sides together, sew the Accent Hat Band to the Exterior Hat Band.
With right sides together, stitch the open ends of the Hat Band together, using a 1/4 inch seam. With right sides together, pin the Hat Band to the Hat Body, matching the back seams. Stitch all the way around.
Add the Face
Pin the Face in the center front of the hat, following the pattern diagram.
Machine stitch the Face in place, using a small zig zag stitch. Hand stitch the Beak and Eyes to the hat, using matching embroidery floss. Dont worry -- the loft of the fleece conceals the stitches, so you don't need to be an expert at embroidery.
Optional: add accents to the eyes and beak with fabric paint or embroider using outline stitches and french knots.
Finish the Hat
With right sides together, pin the hat lining to the main hat at the seams. Stitch them together, leaving an opening in the back.
Turn the hat inside out and lightly press the open seam closed, using a slightly warm iron .
Topstitch around the outside of the hat, using a long stitch.
Make a Bow
With right sides together, stitch closed the long edge of the 3 by 12 inch rectangle. Turn the tube right side out and cut off about 2 inches for the center of the bow. Fold the two ends to the middle and stitch. Wrap the 2 inch section around the stitches and stitch closed by hand.
Hand stitch the bow to the front, just below the penguin's chin.