Sewing: How to Make Hats With Earflaps

Keep warm on a snowy day with an earflap hat lined with fur.

Earflap hats are known by many names, including bomber hat, trapper hat and Elmer Fudd remake. However, the function of keeping your ears warm in cold or windy weather is universal for earflap hats. Learn how to sew your own earflap hat using materials that fit your need. For instance, if you live in the Arctic, accept not less than a fur lining for your custom-made hat. Otherwise, a lightweight fleece may be the best fit to keep your head and ears warm if you spend your winter months in a more forgiving climate.

Things You'll Need

• Newspaper
• Scissors
• 1 yard flannel material
• 1 yard cotton fabric
• Straight pins
• Sewing machine
• Sewing needle and thread (optional)
• 2 shoestrings, 18 inches

Instructions

Prepare the Shapes

1. Draw a 15-by-4.5-inch rectangle, a circle with a diameter of 7.5 inches, and an 8.125-inch circle on a sheet of newspaper. Draw an oval that is 15 inches long and 4 inches wide on the newspaper.

2. Cut out each of the shapes. Cut the two circles in half so you have four semicircles. Cut the oval in half to make two 7.5-inch-long semiovals.

3. Spread 1 yard of flannel material, which will be the liner of the hat, on a flat work surface. Pin the newspaper rectangle, two 8.125-inch-wide semicircles, one of the 7.5-inch-wide semicircles and both of the semiovals to the newspaper using straight pins; don't overlap the patterns. Follow the patterns as you cut out each of the shapes from the flannel. Remove the straight pins and patterns from the flannel material.

4. Spread 1 yard of cotton fabric, which you'll use for the hat's outer shell, on a flat surface. Pin the patterns as you did with the flannel. Cut the shapes; remove the pins from the fabric.

5. Separate the shapes according to the different fabrics on a flat work surface. Turn each of the shapes so the printed or finished side is facing down.

Assemble the Pieces

1. Assemble the flannel fabric pieces first. Place the rectangle piece and one of the 8.125-inch semicircles, printed sides facing, so one of the 15-inch sides of the rectangle is adjacent to the curved side of the semicircle. The rectangle will take on the curvature of the semicircle to form the roundness of the hat. Secure the fabrics using straight pins.

2. Sew the pieces together using your sewing machine; take care to sew over the straight pins so you don't break your needle. You can use a sewing needle and thread to sew the hat together by hand, if desired, but note that the stitching won't be as finished and sturdy if you choose this method.

3. Attach the other 8.125-inch semicircle to the other 15-inch side of the rectangle using the same technique. Remove the straight pins.

4. Place the flannel shell of the hat on your head, seam-side facing out, so you can identify the front side of the hat. Position each of the semiovals of flannel, printed side facing out, with the straight 4-inch sides horizontal to the sides of the hat. Pin the ear flaps so the curved side is covering your ear, while the front edge of the semiovals line up evenly with the front corners of the flannel shell. Sew the ear flaps onto the shell; remove the pins.

5. Assemble the cotton fabric shapes in the same way that you did with the flannel shapes. However, once the pieces are sewn together, turn the cotton shell inside out so the seams are on the underside. Place the cotton shell over the top of the flannel shell so the seam sides are facing each other. Line up the two separate pieces and pin the edges together.

6. Stack the 7.5-inch-wide semicircles of flannel and fabric so the printed sides are facing out and the edges are lined up. Pin the edges and sew around the shapes to form the bill of the hat. Attach the bill, with the flannel facing out, to the front of the hat using straight pins. Place the bill with the straight side horizontal across the front edge of the hat while the curved side is across the top of the front of the hat, as if the bill was flipped up on the front of the hat.

7. Insert 2 inches of an 18-inch-long piece of shoestring in between the flannel and cotton fabric of the curved ends of each of the ear flaps. Pin the two shoestrings in place to create the drawstrings for tying the ear flaps together around the wearer's neck or over the top of the hat.

8. Sew around all of the edges of the hat, including around the curved end of the ear flaps, using a blanket stitch. Sew across the curved edge of the bill to attach it to the hat. Remove the pins before wearing your hat.