Sweater Santa Hat
You'll Need:
1 Red or Burgundy Sweater
1 Cream, White, or Tan Sweater
Sewing Machine
Thread
Hand Sewing Needle
Fleece or Ribbon *This is optional, and just depends on how you make the ball for the end of the hat
Pins
- Cut the sleeves off the sweater, at the seam. From here, try the sleeve on the person's head the hat is meant for, using the cut opening for the head. If it fits, you can move on. If it's too big, pull it tight, and pin where you will need to sew. If it is too tight, cut the seam off. If the seam was already cut off, but is not too tight, move on, as this part is not actually the part that will go around your head.
- Once the arm opening for the sleeve works right and fits around your head, measure the waist or (if it is rounded and not V shaped, boat shaped, or square) neck of the cream/white/tan sweater. To do this, do NOT use a measuring tape, as the material will stretch. Use your head, and wrap it around, pulling it taut. cut this portion of the sweater hem off.
- Pin the two sections together, with the sleeve turned right side out, and the hem inside out & upside down. You want to pin it so the raw side is pined to the sleeve, allowing for the finished side to be unsewn.
- Sew a zig zag stitch around the pinned side, so the hem is firmly attached to the hat. I always leave the two ends of the hem free until it is attached to the hat, then I sew them together, and add another stitch to the top to attach the ends to the hat.
- For the end of the hat, you can do a few things. You could attach a bell to a ribbon, and attach it to the end, pulling the material into as tight of a V shape as you can, and hand stitching it together. You can use fleece to make a fleece fringe ball, and again, hand sew it in. What I did with this particular hat, though, is take a square of the cream sweater, and fold & roll it into a ball shape, then hand stitch it into that shape. From there, I hand stitched it to the end of the sleeve. When I pulled it out, it looked odd, though, so I used ribbon to tie a tight bow in place, then I hand stitched the bow to the hat, so it won't untie.
- The last thing I did was to run a straight hand stitch loosely down the seam of the sleeve, from the opening to the top of the hat. Then, I pulled it, so that the underside of the sleeve gathered up.
They are just adorable, and while a traditional hat is red and white, you can certainly customize it to meet your needs- matching jacket color, different colors for different kids, etc. My oldest daughter and my son both requested red with green instead of white. I made mine with a burgundy colored sweater, and cream sweater, so it looks more old fashioned.
The nice thing about these, are that they are custom fit, so they stay on, and they are warm, so they can be warn as winter hats.
My cost per hat is roughly $.79, as that's how much I pay per sweater at Goodwill. Honestly, though, the cost is cheaper than that, as I still have plenty of the sweater material left over after having made 2 of these.

Next, using a tape measure, measure your head circumference- or the circumference of the person who will be wearing the hat. If it's for a gift, use a comparable sized head. ;)
If you want to use just 1 fabric, you'll want it to be 16-18" wide (tall) for an adult, or 14-16" wide (tall) for a child. If you use 2 fabrics, you want the adult width to be 14-16", and 12-14" for children.
Next, we start the sewing. You want to pick a side of the fabric that you want to face "out". Usually, one side has a slightly fuzzier side. I usually put that side to face inward.
So, lay the fabric with the right side facing down on the work surface (which for me is the floor), then lay the shorter strip along the bottom edge (which can be either side if it's unpatterened, or without a specific direction to the pattern). This strip should also be right side down.
In comes the sewing machine! After it's lined up, sew a straight edge along the bottom edge of the two fabrics. Once it's done, snip the excess thread, and fold the flap so that both of the right side's are facing out.
Now, you want to fold the top edge of the 2nd fabric inward, and pin it into place. Sew another straight edge, this time along the top edge of the thin band of fabric to hold it into place.
You can sew another line under that one, and a third along the bottom half if you choose.
Now that this is sewn into place, you need to fold the fabric in half, so that the two side edges (the short edges) are lined up, and the hat is inside out again. Sew a straight edge down the side, but leave the top 3-4" of fabric unsewn.
From here, you'll need either yur scissors or a rotary cutter to fringe the top 3-4" of fabric. Turn the hat right side out. Gather the fringe, and take a spare peice of fleece fabric to tie around the top of the hat, gathering a "puff ball" of fringe.
Viola! You have a cute hat that took about 20 minutes, and only cost a dollar or two. To keep the price low, and your options high, I recommend scanning the remanent bins every time you go to a fabric store.