Minion Hat

Everybody loves minions, and this hat is not only cute, but will also keep your kids (or you) warm.  This size is for a big kid, but you can easily adjust it to make it smaller.  Please don’t re-publish this tutorial, but feel free to make these hats for Christmas craft sales.

For this project, you will need polar fleece in yellow, blue, black, grey and white.  If you have to buy it by the piece, 1/3 yard of yellow and  1/4 yard of each of the others is enough to make two hats.  If you have scraps that will be even better.

Use a small bowl, cup or anything circular as a template.  Mine is about 4″ diameter.  Trace onto the white fleece with a wash-away marker.

For the non-cyclops, slightly overlap the circles when tracing.  Cut the shapes out.

Use these as templates to cut identical ones out of grey fleece.


Use a smaller circle (about 2″) as a template for the middle of the goggles.

They should fit nicely.

Join these together using a zig-zag stitch along the edge.  Go slowly to keep the curves smooth.  Stitch along both the outside and inside of the circles.

It may be a bit stretched when you finish stitching, but a quick press with the iron will flatten it.

Cut a small piece of black fleece and attach it with a zig-zag stitch.  You can have fun with eye placement.

Cut a piece of yellow fleece 23″ x 11″ (or smaller, if you need to).  Pin the eye(s) in approximately the middle of the piece.

With a zig-zag stitch right over the previous zig-zag stitches, attach the eyes on the top and bottom, but leave a gap at the sides.

Fold in half right sides together and sew a seam with a straight stitch and a 1/2″ seam allowance.  After stitching, turn right side out.

Cut a piece of black fleece 1″ wide and long enough to go around the hat (about 20″ depending on the size).  Tuck one end under the eye and then pin in place around the hat.

Pin all the way around, then tuck into the other side of the eye.

Stitch along the edges of the strap with a zig-zag stitch.

After it is in place, sew down the edges of the eyes that cover the strap.

Cut a piece of blue fleece 3″ x 23″.  Fold to make a loop and join with a 1/2″ seam.  Place the right side of the blue piece to the wrong side of the yellow piece.  Off-set the seams to cut down on the bulk of the seam allowances.

Sew along the edge with a 1/2″ seam allowance.

Turn the blue piece up to the right side and pin onto the hat.  Stitch along the edge with a zig-zag stitch.

Turn the hat inside out and mark the top edge in quarters.

On the outside quarters, mark a line from 1″ down up to the 1/4 marker.

Trim along this line, then sew a seam with a 1/4″ seam allowance.

Remove the centre pin, then open the middle hole.  Fold these pieces in half perpendicular to the other seams.  Mark from 1″ down the edge to the centre point, then cut and stitch each separately, working from the outside edge in to the centre.

You should end up with four seams that all meet in the centre.

It’s done!

Find a smiling kid to enjoy it and you’re good to go.


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