How to Make a Fleece Hat With Ears

    by Karen Ellis

    About the Author

    Karen Ellis has been a full-time writer since 2006. She is an expert crafter, with more than 30 years of experience in knitting, chrocheting, quilting, sewing, scrapbooking and other arts. She is an expert gardener, with lifelong experience. Ellis has taken many classes in these subjects and taught classes, as well.


    Whether you're making a cozy, fleece hat to keep your own head warm during cold weather or surprising a special friend or family member with a handmade gift, you can make the hat extra warm by sewing in a pair of ear flaps, too. Show off your creative side by using colorful or patterned fleece fabric and you'll be so pleased with your creation you’ll want to make them for everyone on your Christmas list.

    Things You'll Need

    • Fleece fabric
    • Straight pins
    • Sewing machine (or sewing needle and thread)
    • Embroidery floss

    Measure the circumference of your head at ear level (including your ears) to determine the fleece fabric measurements. Add 1/2-inch for the seam allowances.

    Cut two pieces of fleece fabric according to the circumference width. Make the length of each piece of fabric 11 inches for an adult, 8 inches for a child and between 6 to 7 inches for infants and newborns, depending on their head size.

    Cut the ear flaps. Make a paper pattern of an equilateral triangle, each side measuring 5 1/2-inches. Cut four triangles.

    Sew the ear flaps, using two of the triangles for each one. Sew the fabric with right sides together and use a 1/4-inch seam allowance throughout. Pin and sew around all three sides, leaving a 2-inch opening along one side. Pull the ear flaps right-side out through the opening of each ear flap. Hand-sew the openings shut. Set the ear flaps aside.

    Sew three sides of the fleece hat; the right, left and top sides, with a 1/4-inch seam allowance and the right sides of the fabric together.

    Fold the bottom of the fleece hat up 1 inch. Pin the fold in place.

    Pin the ear flaps to the fleece hat. Locate the back center of the open end of the hat by matching the side seams together. Place a pin at the center back. Measure 3 inches to the left and pin one side of a triangle ear here along the top of the folded hem at the hat's opening. Measure 3 inches to the right of the center back pin and pin the other triangle ear here along the top of the folded hem. Remove the center back pin.

    Sew around the fleece hat, slightly below the top of the fold, catching the top of the ear flaps as you go.

    Tack the ear flaps at the bottom of the hat on each side by hand, so they stay in place.

    Finish the fleece hat by creating decorative top knots at each side of the hat. Measure down about 1-inch at each top corner. With a matching or coordinating color of embroidery floss, bunch the corner together and tie around it with a double knot. Repeat on the other side. Cut the floss close to each knot.

    • A general head measurement for a man is 23 inches and a woman is 22 inches.
    • Fleece fabric does not ravel; there is no need to double fold hems.


    • Simply Fleece; Bonnie Scott