To start, I must warn you that I am Canadian. Eh. As such, I technically use the metric system for everything. But really I use whatever system is appropriate for the particular tool I'm using, so I switch between metric & imperial. Appologies.
Really don't feel like sewing or embroidering, but want the look? I guess you could buy a tuque and glue some googly eyes on. Or buy it from my store (www.klixcreations.etsy.com). Totally an option.
Step 1: Gather Supplies
-sewing thread (and a sewing machine)
-scissors (or other sharp object)
-fleece in 2 coordinating colours
-temporary spray adhesive
-some sort of measuring implement
-an embroidery hoop. Oh, and an embroidery machine. But if you're lacking in that department, you could also use hand embroidery or applique.
1.2 You'll also want some awesome monster embroidery files. Not sure where to find some? I suggest Monster Factory Design Pack by Urban Threads. I spend far too much money on that site, but their designs are just sooo good.
Step 2: Make a Pattern
Finished tuque sizes should be as follows:
X-Large: 24" circumference, 12" from top to bottom (unfolded, allows 2.75" for brim)
Large (Adult): 22" circumference, 11" from top to bottom (unfolded, allows 2.75" for brim)
Medium (Child or Youth): 20" circumference, 10" from top to bottom (unfolded, allows 2.75" for brim)
Small (Toddler): 18" circumference, 9" from top to bottom (unfolded, allows 2.5" for brim)
X-Small (Baby): 16" circumference, 8" from top to bottom (unfolded, allows 2.25" for brim)
Since the size of your embroidery pattern affects the width needed for your folded brim, choose embroidery designs that will fit well in the alloted brim size, or adjust your pattern accordingly.
Add seam allowance as you see fit. Since fleece doesn't fray, I added minimal seam allowance.