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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

Fleece Knight Helmet Hat with tutorial and free pattern! So many people have made and loved this hat, and you will be sure to love it too!

Fleece Knight Helmet Hat with tutorial and free pattern! via www.wineandglue.com


Let me just start this post by saying that it was so insanely difficult to photograph Gavin in this hat, because he couldn’t break character. He was so busy posing and being a knight that it was seriously almost impossible to get a decent picture that shows off the hat.

Fleece Knight Helmet Hat with tutorial and free pattern! via www.wineandglue.com


Such a ham.

Gavin wanted to be a knight for Halloween, and I decided to make him the frock thing (Nathan is reading this hanging his head in shame that I don’t know the right terminology), and the shield. But we planned on buying him a sword and helmet. The sword we found right away, but we couldn’t for the life of us find just a plain helmet without a bunch of other stuff included. So I decided to make him one! I figured that it could be part of his Halloween costume and then would last into winter as a winter hat.

Homemade Knight Costume on www.wineandglue.com{Please ignore my insanely messy living room . . . and the red foam bowling ball.}


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.

Want to make one too? Gavin’s head is about 22 inches around, and here is the pattern I made to make it!

Here is the pattern on three sheets:


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


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.

You need about a half yard of gray and just scraps of red. The cutting out of the fleece is very straight forward, with the exception of piece 4. You need four piece 4’s, but you want to cut it in such a way that it is cut as two pieces, this way there won’t be a seam in the front of the hat. This is what it looks like all cut out:


I used a half inch seam allowance for the whole project.

The front piece isn’t pictured because I needed to see how it fit first to see how long it needed to be. Make sure you cut out two piece 3’s.

Now sew one side of a piece 1 to another side of a piece 1. Repeat that with the two remaining piece 1’s. (Pictures of this would be helpful huh? Head over to STITCHED.)  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.

Now sew together the two piece fours, leaving the wide piece at the end unsewn. 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 (longest part?). Pin it in place. Sew around.

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!

My sincere apologies for the lack of pictures. I made this on the fly and wasn’t sure that it would even work let along be blog worthy. Head over to STITCHED. The concept is totally the same, and she has step by step pictures. You know, like a classy blogger.

Fleece Knight Helmet Hat with tutorial and free pattern! via www.wineandglue.com

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


    Have a question? Use the form below to submit your question or comment. I love hearing from you & seeing what you made!

  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