Fleece Hatby Ellen March

Original Design for Sulky of America

Fleece Hat– 2 –

Project Overview

This hat pattern is simple to construct and is designed for fleece or knit fabric with 2-way stretch. Use a serger to make construction super simple, or use a standard sewing machine outfitted with a walking foot (for high-pile fleece) and/or a jersey needle (if working with knit). Add an embroidery motif that suits the recipient to personalize the hat, making it a perfect gift for any occasion.

Gather Supplies

Fabric:• 1/4 yard of 60”-wide fleece or knit fabric

Thread:• Sulky 40 wt. Poly Deco™

• Sulky 40 wt. Rayon

Stabilizers:• Sulky Sticky+™

• Sulky Solvy® Water Soluble Stabilizer

Embroidery Pattern (size determined by hat size)

Fleece Hat– 3 –

General Directions:Please read through all the directions prior to starting the project.

Step 1 - Cut Fabric

Print the pattern, and then cut out the desired size. If using a serger, trim away ¼” from the perimeter.

From the fleece or knit, cut two hats on the fold and one brim on the fold, following the pattern indicator for placement along the greatest stretch.

Step 2

Hoop a rectangle of Sulky Sticky Plus, and then score the paper within the inner hoop ring. Tear away the paper, revealing the sticky adhesive. Place the brim pattern over the brim and center the embroidery placement within the hoop. Gently finger-press the fleece in place on the stabilizer adhesive. When satisfied with the placement, remove the pattern piece. Place a rectangle of Sulky Solvy over the fleece in the hoop.

Step 3

Place the hoop onto the machine. Select the desired embroidery design, name or monogram on the machine screen, ensuring it fits within the determined embroidery placement rectangle on the brim pattern. If desired and available, use the perimeter baste function to further secure the layers in the hoop.

Embroider the design, trimming jump threads and changing threads as determined by the digitizer. Remove the stabilizer from the hoop. Gently tear away the excess topper; if any remains, apply a wet cotton swab to the design edge to remove it. Cut or tear away the remaining stabilizer from the embroidery wrong side.

Step 4

Fold the brim in half, aligning the short raw edges; serge or stitch, and then set aside.

Step 5

Place the two hats right sides together, and then serge or stitch the outer edges.

Fleece Hat– 4 –

Note:If using a serger, trim away 1/4” while you serge.

If using a sewing machine, install a walking foot or reduce the presser foot pressure and use a 1/2” seam allowance.

Fleece Hat– 5 –

Step 6

Unfold the hat and refold along the remaining open seams, making sure the seams are aligned and going in opposite directions to reduce bulk; serge or stitch.

Step 7

Place the hat inside the brim with both wrong sides facing out, aligning the hat lower edge with the brim lower edge .Align the brim side seam with one hat side seam, placing the allowances in opposite directions to reduce bulk. Pin or clip the edge generously. Serge or stitch the edge.

Fleece Hat– 6 –

Step 8

Turn the hat right side out, with the brim wrong side facing out. Fold the brim in half toward the right side, concealing the hat seam with the brim upper edge. Fold the raw brim edge ¼” to ½” toward the wrong side as you pin the brim to the hat.

Step 9

Topstitch the brim upper edge to the hat.

Fleece Hat– 7 –

Gift it (or wear it) proudly.