Hi! I’m Stacey and you can usually find me over at Boy, Oh Boy, Oh Boy Crafts or my shop, Beatnik Kids, where you’ll find me designing and sewing kids clothes. With three boys in the house, a lot of my sewing tends to revolve around the characters they love and games they like to play. Whether it’s pirates, dinosaurs, or superheroes, there’s always some type of dress up item being requested. Hats are the easiest costume piece to make and tend to get the most use because they’re easy-on, easy-off.
Today, I’m sharing a pattern and tutorial for one of the boy’s most beloved warriors- the Samurai.
– Free Samurai Hat (Large and Small) (pattern below)
– 1/2 yard fleece fabric
– Scrap of heavyweight interfacing
– Coordinating thread
Download the Pattern Below:
How to make a Samurai Hat for kids tutorial
Please read through all the directions before beginning this project.
Place the two top pieces, right sides together, pin and sew using a 1/4 inch seam allowance. Turn right side out and press well.
Pin two flap pieces, right sides together and sew around the outside edge using a 1/4 seam and back stitch at the beginning and end. Repeat for the other pair.
Sandwich the flap pieces (facing inward) between the bottom front and bottom back pieces, Pin and sew the side seams.
Place the top portion of the hat, right sides together and pin along the upper raw edge. Make sure the flap pieces are kept out of the way. Sew using a 1/4 inch seam. Turn right side out, press the seam down and top stitch.
Trim the interfacing a 1/4 inch around each edge. Then sandwich it between the two visor pieces. Sew around the outside edge using a 1/4 inch seam, back stitching at the beginning and end.
Pin just above the top of hat and sew to the top using three vertical lines.
Start with the middle of the visor and then sew two more vertical lines about 2 inches apart.
Repeat steps 1-4 (omitting the flaps) for the lining pieces.
Place the lining piece over the main fabric, right sides together, and pin all around the outside edge. Be careful to keep the visor and flap pieces out of the way. Sew using a 1/4 inch seam allowance, and leave a 4 inch space for turning on the bottom.
Turn the hat right side out, press (making sure to press the opening seam in), and top stitch.
And you are finished. Feel free to add embellishments like a button or fabric paint to fancy it up a bit, or leave it as is. Either way, your favorite, little warrior will be happy as can be!
You can check out more of my fleece hats here. (There’s a cute Knight hat that I know you’ll love.)
I also have this Dragon Vest here. Perfect for little boys to run around in.