How to Make Philo Beanie Hats

Commonly worn by snowboarders and skaters, philo beanie hats are quick to make and easy to wear. It's a warm, stylish hat that can be customized to the wearer with a wide array of colors and sizes that make it fun to sew.

Things You'll Need

• Tailor's measuring tape
• 1 yard of muslin
• 
Pins
• Tailor's chalk 

• 1 yard of medium-weight fleece 
or wool
• 
Thread in color to match your fabric
• 
Sewing needle
• 
Sewing machine 

• Safety pins 

• Ruler 

• Yarn (for optional pom-pom)

Instructions

1. Measure the circumference of the wearer's head using your tape measure. The tape measure should form a circle around the crown of the head from the top of the forehead around to where the ears join the head and around the back to the base of the neck. Write this measurement down.

2. Decide on the look of your beanie. Choose a color and pattern. Think about whether you want a fold in the beanie that creates extra texture, or if you want a smooth hat. Think also about how you want to finish the top--whether you want it to be plain or finished off with a pom-pom. If you want earflaps, you'll need to sew them on separately.

3. Cut muslin 1 inch wider than the circumference of the crown you noted on your paper and 1-1/2 feet long. Fold your muslin so that the length remains the same and your circumference has been cut in half. Pin and baste with a 1/4-inch seam allowance. Place on the wearer to test the comfort around the crown of the head. If you want a fold placed in the circumference of the beanie, make it now. Take the muslin off and pin this fold down. If you want earflaps, cut equilateral triangles that are 5 inches on each side. Safety pin two of the corners of each triangle to the underside of the brim on opposite sides of the hat allowing the seam to lie in the middle of the two flaps. The seam will form the back of the hat.

4. Place the hat back on the head and, using your tailor's chalk, mark where you want the hat to end. Take the muslin off again. Mark the center of the width of your muslin and cut downward from the top to 1 inch before your mark. Refold your muslin until the basted seam, facing upward, is at the center. Cut another slit down your seam and the back side of the muslin tube the same length as your last one. Place the muslin back on the wearer's head. Carefully pin the crown so that 4 triangular pieces meet to form the top of the head. Remove and baste pieces in place. Trim excess away, leaving a 1/2-inch seam allowance. Turn right side out and check for fit and style. Take out the basting and unfold. You now have a hat pattern to work from.

5. Using your newly made pattern, cut out your fleece fabric, making a 1-inch seam allowance everywhere but the bottom, where you should make a 2-inch seam allowance. Baste into place the same way you did with your muslin. Try it on the wearer with it turned inside out. Check the fit. Turn right side out and check the fit again. If there is a fold in the beanie, tack in place from the inside. Sew the seams down using a sewing machine and check the fit again. Press seams. Hem the hat. Turn the raw edge under 1/4 of an inch, iron and and sew in place. Turn under again at 1-3/4 inches, iron and sew in place.

6. Add earflaps if desired. Cut out 4 triangles from your fabric. Press the right sides of 2 triangles together and sew 2 sides together using a 1/8-inch seam allowance. Turn right side out and turn the raw edges under. Iron the crease in place and sew together using a 1/8-inch seam allowance. Repeat with the other triangle. Pin in place to the underside of the brim and sew securely to the hat using small under stitches.

7. Add a pom-pom if you wish. To make a pom-pom, wrap yarn around a ruler 15 to 20 times and cut yarn. Take looped yarn off the ruler and tie securely in the middle with another piece of yarn. Clip loop ends and fluff. Sew in place on top of the beanie.