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Fleece Knight Helmet Hat (Free Pattern)


posted: 11/19/13

This post may contain affiliate links. Please read my disclosure policy
This post may contain affiliate links. Please read my disclosure policy

This Fleece Knight Helmet Hat with tutorial and free pattern makes the perfect Halloween costume. So many people have made and loved this hat, and you will be sure to love it too!

little boy in a homemade fleece hat shaped like a knight's helmet

If you have a little knight in your life, this is the perfect thing to make for him. This is a great beginning sewing project. Fleece is so forgiving and easy to work with. This project is bound to be a success.

little boy in a fleece knight hat

Pattern for Helmet Hat

The base for this hat comes from this amazing Dinosaur Hat from Stitched.  I switched out the spikes for the red piece in the back, and changed the ear piece to be a little more square. Then I added a front piece with buttons that can flip down, flip up, or just be taken off.

This hat was made for a head that is 22 inches around. You can can scale the pattern up and down accordingly.

Here is the pattern on three sheets:


Download page 1 here  |  Download page 2 here  |  Download page 3 here

little boy in a homemade knight costume


  • Half a yard of gray fleece
  • Less than a quarter of a yard of red fleece
  • Two red buttons

How to Make a Fleece Helmet Hat

Step one: Print out the pattern. Once you have printed out all three sheets, cut all the pieces of paper out, and tape together piece 3a to piece 3b and piece 4a to piece 4b.

Step two: Cut out the pieces. Cut four “Piece 1” pieces from the gray fleece. Cut two “Piece 2” pieces out of red fleece. Cut the pattern pieces for 3a and 3b and tape them together. Then cut two “Piece 3” pieces. Repeat this process with 4a and 4b. The photo below shows all the pieces cut out with the exception of piece 3.

pieces of fleece cut out to make a knight hat on a floor

Step three: Pin the pieces together. Line up the duplicate pieces (for example the “Piece 4” pieces you see in the photo below). For the top of the head, it will pin together to make a hat shape. There are helpful photos of this in the tutorial over on STITCHED. But do not pin it all the way to the top.

Step four: Sew the top of the hat together. Use a half inch seam allowance for everything. Now sew one side of a piece 1 to another side of a piece 1. Repeat that with the two remaining piece 1’s. Sew the red pieces together and flip inside out. Now you can complete the top of the hat. Pin the two sides of the hat together with the red part on the inside sandwiched between the right sides of the fabric.

Step five: Make the bottom of the hat/ear flap. Now sew together the two piece fours, leaving the wide piece at the end open. Once it is sewn together, flip it so that the right sides of it are together, and sew down the length of the wide part. This will make it a full circle.

Put the top part of the hat inside the ear flap circle. Make sure that the red piece that goes in the back is lined up with the widest part of the ear flap that goes in the back. Pin it in place. Sew around.

Step six: Make the front part of the hat that moves up and down. Sew the two piece 3’s together, leaving a small two inch gap. Flip it inside out, and then top stitch around it.

With your kid having the hat on very carefully pin piece 3 in place, add buttons, cut holes in piece 3, and you are done!

little boy posing with a fleece knight hat.

Other Easy Halloween Costumes

We have other easy Halloween costumes too! Tackle one of these simple projects next!

Hi! I'm Lisa Longley, and I am committed to giving you simple dinner ideas and recipes that are easy to make; recipes that will fill your home with joy. I am the owner and author of SimpleJoy.com and I'm so glad that you are here.

Reader Interactions


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  1. Ayelet says

    This looks wonderful! I have two boys that are happy to be knights for Halloween. Do you have any asstimation how much extra fabric you need for the armor and the sheild? Are those from the same fleece or felt?
    Halloween is right behind the corner…. :-)

    • Lisa Longley says

      I totally missed the boat on replying to this comment Ayelet! The shield and the armor are made out of fleece, and I’m pretty sure I got two yards of the dark fleece.

    • Joke says

      What a great had! My sun wants to be a knight at carnaval and I want to make him you’re helmet but … how do I reduce the patern?… My son’s head is 20 inch…

      • Lisa Longley says

        So, I would suggest you can either for for it with this pattern for a 22 inch head because before long he’ll grow into it, and it’s not like it will be SO BIG that it will flop over his eyes. Orrrrrrr, because 20 divided by 22 is 90.9, when you print this you could put in 91% into your printer settings so it will print smaller. Does that make sense?

  2. veerle says

    one happy knight and one happy mom … the most comfortable helmet ever! thanks!

    • Lisa Longley says

      Yay! Thank you!

  3. Andrea says

    The “frock thing” is called a tabard. It originally would have been a piece that went over the armor to show off ones heraldry.

  4. Leslie says

    Thank you for this! I just whipped one up for my great-nephew (soon to be 5). After I fixed the broken strap on a homemade shield he had he said he needed a helmet. I introduced him to Pinterest and he chose yours! He’s tickled with it!

    • Lisa Longley says

      Thanks Leslie!! I’m so glad it turned out well!

  5. Gisela says

    Thank you very much! you have saved me for my son’s Christmas show. Kisses from Mallorca (Spain).

    • Lisa Longley says

      That’s great!

  6. Angela says

    thank you for posting this, my son is happy with his helmed. Hij wanted to be Mike the Knight so made it in blue.

    • Lisa Longley says

      You are welcome!

  7. Marlene says

    Hey !
    Many thanks for the tuto, I’ve just finished a helmet for my 4 years old son.
    He’s very proud of it (and me too !)
    It was not so easy for me because of different units (I’m french) but with your very usefull pattern it was ok !
    I’ve planed to join a picture but it seems to be not possible in this comment box…

    • Lisa Longley says

      I’m so happy you liked it!

  8. Bettina says

    Hello, i want to sew the knight helmet. I don’t understand for what ist the piece no. 2? Regards Bettina

    • Lisa Longley says

      Piece 2 is for the red piece that goes on top of the helmet.

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5 Secrets to Stress Free Dinners



5 Secrets to Stress Free Dinners