DIY Ear Flap Hat FREE Pattern & Tutorial

A simple tutorial on how to make a DIY winter hat with earflaps using a free printable pattern. 

This winter hat has a finished circumference of 23″ – it fits all the adults in my family comfortably as well as my son who was 7 when I made him his. I also have a smaller version of this Earflap hat here which has an 19.5″ circumference. Check it out here.

I get asked often if woven can be used for the shell of the hat. Definitely! You can use ANY kind of fabrics for the shell – corduroy, leather, or even a windproof waterproof fabric. The lining is something you would want to be as soft as possible as it will be against your ears and face. Fleece, Sherpa, and faux fur are excellent options. 

If you do make this earflap hat, be sure to share your beautiful pictures on Instagram or Facebook with #zunessewingtherapy. I’d love to see your style!

Ok, let’s get started! 

Shell – 1/4 yard
Lining – 1/4 yard
Print Pattern – This pattern is FREE to all my newsletter subscribers. Check both your inbox and junk folder for the confirmation email. Be sure to have your pop up blocker disabled. Print from a laptop or computer.

Cut out all the pattern pieces from your shell (outer layer) and lining (inner layer) fabrics. 

1. To make the CROWN, sew the panels in 2s with a 1/4″ seam allowance. Fold the SIDEBAND in half and sew with a 1/4″ seam allowance.

2. Then, sew the 4 panels together with a 1/4″ seam allowance. Leave a 2″ opening on the lining so the hat can be pulled right side out later.

3. Right sides together, sew the crown to its corresponding SIDEBAND.

4. For the straps, you can use a long strip of fleece folded and sewn in half. Ribbons, like grosgrain and velvet, are also a cute alternative. Pin each strap on to the earflap of the lining. (Right sides together if your strap has a right/wrong side). Sew with a 1/8″ seam allowance. 

5. Pin the shell and lining right sides together. Be sure to pushed the straps inside the hat so they don’t get caught in the stitches. Sew with a 1/4″ seam allowance.

6. Pull the hat right side out through the 2″ opening along the lining’s crown. You can handstitch the opening close with a ladder stitch or edge stitch with a machine. 

9. Topstitch along the edge of the sideband.

And you’re done!

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