Aviator Hat (Adults and Kids)

Project preview

This video is for members

Join Lulu Ferris to watch the complete class and sew along at your own pace.

What you’ll make

Sew a warm aviator-style hat with a shaped crown, ear flaps, and a front visor. The design is available for babies, children, and adults.

The demonstrated hat pairs an outer fabric with a warm lining. Optional ties secure the ear flaps, while snaps or hand stitching can hold parts in their raised positions.

What you’ll learn in this class

Pair fabrics for the visor and ear-flap section.
Sew curved pieces and trim them for smooth turning.
Build the crown from mirrored upper panels.
Position and baste the visor and ear flaps.
Join the outer hat and lining.
Turn the hat through the lining opening.
Close the opening by machine or invisible hand stitch.

Fabric suggestions

Choose warm winter fabrics. The examples pair quilted nylon with sherpa fleece and corduroy with fleece.

Fabric thickness determines the best needle and whether a walking foot will help at bulky intersections. Check heat sensitivity before pressing synthetic or quilted fabric.

Make it your own

Add ties to fasten the hat under the chin. Snaps can hold the ear flaps upward, while small hand stitches can secure the visor in its raised position.

Omit snaps and close the lining opening invisibly if you want the hat to remain reversible. The visor can also be worn lowered.

For another shape, try the Earflap Hat.

The jacket shown with this project is the Sam Jacket.

Pattern and sizing

The included A4 pattern covers sizes from 6 months through M–L adult, with baby, child, S–M adult, and M–L adult options.

The video class and printable A4 pattern cover the outer hat, lining, ear flaps, and visor.

Pattern & materials

Patterns are included with membership

Active members can download every available PDF and materials list.

Project gallery