Introduction: Winter Knight

About: Professional work in various electrical and mechanical fields, obscure sense of humour and typically willing to help... Currently under contract designing environmental monitoring equipment.

I wanted to make this from fleece but was initially unable to find the right shade. It turns out that IKEA had exactly what I was looking for.


1/2 yard of fleece

30mm buttons

Red yarn

Sewing supplies

Step 1:

The patterns were created using a head form. The form was wrapped with stretch wrap, foil and duct tape.

The duct tape was the cut to lay flat.

Since fleece is really forgiving I was then able to reduce the top of the top parts in half from 8 to 4. I tried to make it symmetrical as possible.

This produces the top beanie part. the rest was created similar to cover the face and neck. This was meant to have the only visible seam in the back.

The face cover needed to be able to rotate upwards and downwards, this was accomplished using 2 buttons.

I have included the 3 necessary patterns for printing on 2 legal sheets. Print at 100% for adult size.

Step 2: Attach the Pieces Together

I use sewing clips to hold the pieces together.

Begin by pairing the pieces together. You should have 4 pairs of triangles and 2 of the remaining shapes.

The triangles are clipped then sewn along one long edge in the pattern this is Side A on one piece to Side B on another This gives 4 pairs of connected parts.

From here, open 2 connected parts and clip the remaining long edges together Sides A to B on each half. Sew along the outer edge, leaving the bottom Side C open.

Repeat this for the other 2 pairs and you should be left with 2 beanies and 2 remaining Neck Guard parts.

Mark the inside centre line of the Front fold on the Neck Guard

With the beanies seam side out, align the Neck Guard with the centre line along one upright seam. Clip along the Side C edges all the way around.

Clip the back to remove any left over material the sew Side D seam first.

Now sew along Side C edges to connect the pieces together.

Repeat this with the other set.

Now clip the 2 halves together along the Side E edge, with the sewn seams outward.

Sew the 2 halves together Along Sides E leaving 4 to 6 inches open at the rear of the hat assembly.

Use this opening to turn the entire hat right sides out.

Tuck the unsewn edge at side E near side D in then sew along the entire face and neck opening about 5mm from the edge. this will finish the entire neck and face opening.

Step 3: Button Placement

A hinge was needed and I chose to use a button for this.

I needed a 30mm button but couldn't find one the looked good. I chose to print one from grey ABS.

It looked boring and out of place so I made a shield shaped button. This turned out great, I chose to use red thread to attach it and the resulting cross shows very Knight like...

The button placement is shown on the pattern.

Step 4: Face Cover

The face cover is in 4 pieces, these are first sewn along the curved Side X edge.

the two assemblies are then joined all the way around the Side Y and Z edges leaving 2 to 4 inches open along one side. This is used to turn the face cover right side out.

The opening edges are tucked inside then the entire part, Sides X, Y and Z edge is sewn to finish the face cover.

The button holes are marked on the pattern.

The button holes are perimeter sewn then cut open with a razor knife.

The face cover is positioned on the button from the bottom edge first.

Step 5: Plume

The plume is optional and I created it using yarn.

The plume holder is a scrap piece of fleece that has sewn edges it is approx 8.5 inches by 2.5 inches

I used a 15 inch piece of floor mat foam to wrap the yarn on. it is 2 layers about 6 inches wide.

One end of the looped yarn is sewn down to the inside of the sewn previously sewn rectangle using another scrap piece of fleece on top

This was tightly rolled and hand sewn together along the seam.

This roll was then hand sewn to the top of the hat at the crossing of seams.

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