How to Make a Boys Aviator Hat
Ever wondered how to make a boys aviator hat. I came across this aviator hat pattern in the December 2017 issue of Sew Magazine and had to share it with you. It is an adorable boys fur aviator hat that is perfect for boys of all ages. The pattern has sizes ranging from boys to men and is an easy project to make.
For the outer part of the hat I used a flannel remnant that I had in my stash but for the fur I ordered directly from Fabric.com and got it in a matter of a week. They had a great variety of furry fabrics that would be perfect for this project. If you would simply like to buy a hat like this you can get one by clicking on this aviator hat link. But I highly recommend tackling this project. This is a beginner sewing project and it is a fun one.
What you will Need:
- Free Aviator Hat Pattern
- Outer Fabric depends on the size of the hat you are making.
- Furry or lining fabric depends on the size of the hat you are making.
- Hook and Loop Tape (Optional)
Step 1: How to Make a Boys Aviator Hat
Tape the free aviator hat pattern pieces together as shown in the pattern.
Step 2: How to Make a Boys Aviator Hat
- Hat Top: Cut 1 of outer fabric and lining
- Ear Flap: Cut 1 on the fold of both outer fabric and lining
- Peak: Cut 1 of outer and lining
- Hat Side: Cut 2 of outer and lining
- Chin Strap: Cut 2
Step 3: How to Make a Boys Aviator Hat
Create the chin straps by folding each strip lengthwise and pressing. Open the straps and fold each side toward the middle and press. Fold in half to create a four layer strap. Fold one of the shorter ends inward to enclose the raw edges. Top stitch along both sides of the strip. Add the Hook and Loop tape to each of the strips.
Step 4: How to Make a Boys Aviator Hat
Pin the outer and the lining fabric together right sides together and sew along the curved edge. Clip the seam allowances at the curves. Turn the ear flap right sides out and press. Top stitch the ear flap along the curve.
Step 5: How to Make a Boys Aviator Hat
Make the peak by pinning the outer and the lining pieces right sides together. Sew along the curved edge. Clip the curves and turn right sides out. Top stitch if desired.
Step 6: How to Make a Boys Aviator Hat
Pin the top outer piece to the sides at the curved edges starting in the middle and easing as you go. Sew. Press the seams toward the center and top stitch. Repeat with the lining fabric leaving a 2 inch opening for turning.
Step 7: How to Make a Boys Aviator Hat
Mark the center of the straight edge of the peak. Join one side of the hat top with the peak right sides together matching the centers. Pin along the straight edge.
Step 8: How to Make a Boys Aviator Hat
Mark the center of the straight edge of the ear flap and place it at the center back of the outer hat. Place the ear flap and the hat back right sides together. Match the centers and pin. Baste around the bottom edge to attach the peak and the ear flap.
Step 9: How to Make a Boys Aviator Hat
Place the outer hat inside the lining hat right sides together, leaving the ear flap and peak tucked away. Pin around the bottom of the hat.
Step 10: How to Make a Boys Aviator Hat
Sew the hat catching all of the layers as you go. Turn right sides out through the opening you left in the lining. Top stitch starting and finishing at the front. Sew the opening in the lining using ladder stitch. Hand tack the peak near each top seam to hold it up. Your hat is now finished and you have now learned how to make a boys aviator hat. I hope that you have enjoyed this beginner sewing project.
I hope you enjoy this project. If you want more sewing and crafting projects sign up for our newsletter and get your free eBook of 15 handbag patterns and tutorials.