Time to make: 3-4 hours from start to finish.
Polar Fleece (about 2 feet)
All Purpose Thread
Velcro or snaps
Large Craft Eyes (I used 35 mm)
Download and print the pattern images in this step.
Step 1: Cut Out Pattern Pieces
To save time, fold your fabric in half so that you are cutting out two pieces instead of one.
Place on polar fleece and cut out pattern.
I cut mine free form and just held the pattern down, but it might be a better idea to pin the paper to the fabric first.
Note: Before cutting decide if you want a hat brim that is stretchy or one that fits more precisely. If you want a stretchy brim, which I recommend, pull on your fabric to figure out which way the fabric stretches. Once you've got that place your pattern along the direction of the stretch.
If you don't want your brim to stretch place it in the direction the fabric does not stretch.
Step 2: Sew Hat Panels and Fin
Take the triangle shaped fin pieces and place them together with the outside of the hat on the inside. Sew along the short edges all the way around the large edges. Be sure to leave the small inside triangle shape open.
Flip the fin piece right side out. Use a pen or skewer to pop the points out.
Sew a 1/4 in around the edge of the fin. This adds stability and texture.
Step 3: Attach Fin to Hat Panels
It is important to make sure the middle of your fin aligns with the seam lines of the hat panels. Otherwise the fin will be sewn on crooked.( Which could be fun!)
After pinning sew 1/4 in from one end of the hat to the other. Be sure to leave the bottom of the hat open.
Step 4: Attach Hat Brim.
Fold this piece lengthwise with the good side of the fabric on the outside. We don't need to flip this one inside out.
Pin the open end of the brim to the bottom of the hat panels. The closed end of the brim should be on the outside of your hat, pointing towards the fin.
Sew 1/4 in along brim. If you want this part to look a bit more refined use a stitch that goes over the edge of the fabric or a serger if you've got one. I think most sewing machines have fake serger stitches these days.
Flip brim down.
After the brim is attached lay the hat so that the hat is folded in half from the side. You should have the front and back visible. Sew 1/4 in from the seam along the front of the hat(don't go over the brim!) and stop just before the fin. This will add a nice little ridge detail along the front of the hat which provides stability to the hat top. It keeps your fin perky!
Step 5: Tentacle Time!
Match your tentacle pieces up with the fabric inside out. 2 pieces per part.
Sew along edges leaving the bottom bit open. If you sew this shut you can't invert the tentacle.
Flip your tentacles inside out by pushing your thumb up through them and rolling the fabric down with your other hand.
Step 6: Attaching Tentacles
I keep the brim flipped up for this part. Try to sew directly where the brim was sewn to the hat. you may want to sew over this a couple of times because the long tentacles get tugged a lot.
Look at your paper hat pattern and match up the small tentacles where indicated on your fabric. They should be roughly 1 tentacle width apart and fold over the flipped up brim a bit.
Fold the open part of the tentacle down with the corners angled towards the center of the tentacle. This is to hide the fabric ends.
Pin the tentacles down where you want them and sew along the folded top part of the tentacle.
To keep your tentacles down try this.
Cut small squares of velcro and attach them to the underside of your tentacle and the flipped up side of your brim. Make sure you line up the pieces before attaching them.
I used self adhesive industrial strength velcro.
Be sure that the female(soft) piece of velcro is what you use on the hat brim. If you flip the brim down you will be happy you did! The male velcro is very scratchy and abrasive on the skin.
Step 7: Attach the Eyes
However, feel free to put your eyes anywhere you like, and as many as you like!
On most craft eyes there is a metal bit that you snap on over the stem of the eye. This leaves the stem sticking out which I think is uncomfortable, let alone dangerous. Using a dremel with a sanding disc I remove the excess stem. This is usually short enough for the kinds of eyes I use. However, if you still have more stem sticking out I've been using fasteel, which is a two part epoxy putty, to cover the ends. It is super hard and cures within minutes. I then cover the fasteel with a bit of the fleece. I think I may have super glued it on, so ghetto...