DIY Birthday Hat Tutorial

I wanted to make a birthday hat for Little Man, but I couldn’t really find a tutorial that I liked. 
So I let my own creative juices flow, and here is what I came up with. 
Here is an easy tutorial I have put together to show you how it was made…
First, make a pattern like the one pictured below. I made mine out of the side of a cereal box. You may have to make some adjustments to the measurements to get the size and shape you are looking for. 
Trace your pattern onto a piece of fusible fleece and cut it out. I found my fusible fleece sold by the yard at my local craft store.
Iron the fleece to the WRONG side of the fabric and then cut the fabric out around the pattern, leaving an extra inch or so of fabric around the bottom.
With RIGHT sides of the fabric together, fold the hat in half and sew along the edge using a very small seam allowance.
Carefully turn the hat inside out.
Tuck the bottom of the fabric under and glue inside the hat using a hot glue gun. Because of the curve of the hat, take it slow and pull the fabric tight as you go. There will be some overlapping of fabric.
Now the fun part! Using your hot glue gun, decorate your hat. 
For this hat, I used red ric-rac (found in the ribbon section at the craft store) and a circle and number I made using regular craft felt. 
(Tip: Make your own stencils by simply typing your desired number/letter in Microsoft Word and choosing a large font size. Then simply print, cut out and trace.)
For the finishing touch, I made a pom-pom out of red yarn using these instructions. I left the tails of the pom-pom long and then fed them through the opening at the top of the hat.
Once they were through, I pulled them from the inside to make sure the pom-pom was tightly in place, and then turned the hat upside down and “dribbled” a pool of hot glue down into the tip of the hat. After it dried, I trimmed the tails.
Last, but not least, cut a string of thin elastic measured to fit your child, and hot glue to the insides of the hat. 
And there you have it. A cute birthday hat custom made by Mama!
If you make your own, I’d love to see. Please leave me a comment with a link or email me a picture!


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  1. Yay! What good timing…my little one turns two on Wednesday and I decided this morning that I wanted to make hats instead of buying them…birthday goofiness awaits! Thanks for sharing!

  2. Thank you for this awesome tutorial! I found your blog by googling “superhero birthday party” my son will be four in May, your blog is my new favorite 😉

    Hope to see you around blogland 😉

  3. I have mom brain and am having a hard time with the measurements. like how many inches there are vertically?


  1. […] take that back. I did. I just didn’t want to! Bahaha. I got my inspiration from this blog, although the more I look at it, the more I realize I didn’t follow her directions […]

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