Step 1: Materials
-At least 1/3 yard yellow fleece
-1/3 yard blue fleece
-Black fleece (only about a 1x22 inch strip)
-Grey fleece (enough for the goggles)
-White fleece (enough for the eyes)
-Brown fleece (just a few inches for the pupils)
Step 2: Cutting Everything Out
Hat: You can download the pattern on the previous step to get the general hat shape. Just make sure it's around 11 1/2 inches along the bottom, and about 8 1/2 inches tall. Cut this part out in the yellow.
Brim: Cut out two blue 11 1/2 x 5 inch rectangles.
Band: This is out of black. Fold the yellow hat part up in half to get your length. Cut about 1 inch thick, on the fold so it's one long piece. (Fifth Picture)
Eyes: Find something round (diameter about 2 inches) to trace onto white fleece. It doesn't need to be pretty because the edges will be hidden under gray.
Goggles: Cut about half an inch larger than the white, all the way around. Then cut out the middle of the circle.
Eye Pupil: I used 1 inch circles of brown, with a smaller black circle inside.
Smile/Hair: Use black fleece scraps to make a smile and some pieces of hair.
Lay out your pieces to make sure you have everything.
Step 3: Putting Darts in Top of Hat
Sew along this line to make a dart, decreasing the size of the top.
Step 4: Sewing the Hat Together
To add hair: Take three small strips of black fleece and insert at the darts. Pin on either side. Sew all the way around the outside edge, back-stitching over the hair for extra strength.
Step 5: Adding the Black Band
Sew along the entire edge of the black.
NOTE: When I made this hat, I sewed on the blue brim before doing the face. This makes it much harder to sew on the details later. Don't sew on the brim until everything else is done.
Step 6: The Eyes
Pin the brown iris on the white, and then sew around the edge. Do the same for the black pupil.
Cut a small smile shape from black fleece and sew on below the eyes.
Step 7: Sew on the Brim
Next you are going to attach the brim to the hat. Turn the brim "upsidedown" and put it on the outside of the hat. Both the unsewn edges should match up. See pictures 4 and 5.
Sew along this edge.
You have finished your minion hat!