Vulture Aviator Hat

Not only is it just fun to dress up a stuffed animal, it inspires the imagination! Imagine a vulture soaring high in the sky with her aviator hat on, setting the stage for a skilled pilot who is also the plane. This hat is designed to fit my Pudgy Plumes Vulture Doll.

What You'll Need

  • – Fat Quarter Fabric for the outside of the hat (I used faux leather.  Felt, cotton or other fabrics work also)
  • – Fat Quarter Fabric for the inside of the hat (I used suede. Felt, cotton or other fabrics work also)
  • – Template page (found at the bottom of this page)
  • *you won’t need the whole fat quarter for each 
  • -Notions: pins, thread, scissors, sewing machine, etc

Step 1: Cut the hat pieces from fabric, one set for the inside and one set for outside.

Step 2: Place the hat gusset and one hat side right sides together. Align the “A” notch on one side of the hat gusset with a hat side, pin in place. Then align the corner of the “B” end of the gusset with the “B” notch on the hat side and pin in place. Continue aligning the edges together between “A” and “B” and pin in place.

Step 3: Sew between “A” and “B” using a 1/4 inch seam allowance. Clip the curve. Repeat with the opposite hat side.

*Repeat Step 2 & Step 3 with the pieces for the inside of the hat.

Step 4: You should have completed inside and outside hat pieces. Turn the piece that will be the outside of the hat right side out, leave the inside piece wrong side out.

Step 5: Place the inside hat piece right sides together with the outside hat piece, by sliding it over the top. Align the “A” notches together, the “B” notches together and the “flap” together first and pin in place. Then continue aligning and pinning the edges together all the way around the hat.

Step 6: Sew around all the raw edges using a scant 1/4 inch seam allowance, do not leave an opening.

Step 7: Clip the curves. Cut a slit in the inside hat panel and turn right side out. You can leave the slit as it is if you’d like or you can stitch it closed sewing by hand using a ladder stitch.

Step 8: (Optional) Your hat is now right side out and if you’re happy with it, you can be done now. Or, to add more definition and embellishment to it, add a topstitch. Topstitch around all the edges using a scant 1/8 inch seam allowance. I also topstitched along each side of the gusset seams to give further definition.

All done! Now, you can add some fun ‘aviator goggles’ too…

Here’s a great image for Pinterest!  Pin now and save this project for later.