This is the last polarfleece post for winter, I promise!
Over the years, I’ve made more than five hundred of these beanies. I started in 1996 when Big Boy was in preschool, making them to sell at the school fete. Back then, polarfleece was Polartec, and it was expensive and high tech and hard to come by. I bought the fabric online from the US, turned it into kids’ hats, and sold one to every parent who walked by that cold winter’s morning.
A few years later, a handful of sewing friends and I turned these out by the truckload and donated them to charity. They were lightweight, soft and extremely warm – the perfect thing for someone sleeping rough.
Last week, I decided that young Evan desperately needed a hat, so I set up the sewing machine, rummaged around to find the pattern, and sewed one for him. And then I was off! My dear friend Peter Bryenton asked me if I had a beginner’s pattern he could use, so I tracked down the guide I’d written for the charity sewing and sent it to him.
To make it easier to understand, I made up a sample and took a few photos to send to him as well. These were taken at 10pm, so they’re not terribly polished, but I thought I’d write them up anyway in case anyone else is interested.
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Click here to download the pattern: Adult Polarfleece Beanie. It’s sized to print out on A4 paper, and the pattern piece should be 42cm (16½”) from the point to the base. Again, apologies for the lack of polish – it was written a long time ago!
1. Buy half a metre of decent quality polarfleece (200 weight is great, if you have a choice). This should give you enough for two hats. Cut out four identical pattern pieces, all with the stretch going ACROSS the piece (not up and down – this bit is important).
2. A note on polarfleece, it curls to the WRONG SIDE when pulled across the stretch. It doesn’t fray, so it won’t need any edge finishing. With a piece of tailor’s chalk or a bit of sticky tape, mark the wrong sides so you don’t get confused.
3. Place two pieces RIGHT SIDES together. Stitch from the point to the base down one side. I use the width of my half my pressure foot as the seam allowance (about 6mm) and sew with a long (say 4mm) straight stitch. Repeat with the other two pieces. My sewing machine has automatic tensioning, but if you’re using one with a manual tension, you might need to loosen it a little to handle the thicker fleece.
4. Place the two halves RIGHT SIDES together. Pin.
5. Stitch from one side all the way up in a long arc through to the other side. Use the long straight stitch again and the same seam allowance. When you get to the bit in the middle where the seams meet, open the seam allowances out flat and sew across carefully.
6. Flatten out the seams with your finger – they should press quite flat. Never use an iron on polarfleece or it will melt. And really, this isn’t precision sewing! Trim all your end threads off neatly as you go, even though I didn’t. (Well, I did, but after I took this photo.)
7. With the WRONG SIDE out, fold up a cuff of 12cm (4.75″). Pin in place. Try to open out and flatten the seam allowances to make them easier to sew. I think this is the only really fiddly bit of the whole process.
8. Using the free arm of your machine, stitch the cuff up using a long zigzag. I use a 3mm wide, 4mm long setting.
9. Turn it RIGHT SIDE out, fold up the cuff and voila!
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I’ve been cheerfully sewing up beanies for the neighbourhood littlies. The snake hat was for my friend Beej…
For Lucia’s and Rosie’s hats, I’ve added small pieces of folded ribbon, taken from the treasure bag of trim that Nancy sent me earlier in the year…
The pattern I’ve provided with this tutorial is for a medium to large adult sized hat. If anyone needs me to trace and scan a small (toddler) or medium (child or small adult) sized piece, please let me know. Stay warm folks! ♥
Edit: As requested, here are the smaller sized patterns:
Beanie pattern: Small and Medium
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My friend Beej just sent me this photo. She put her beanie on to catch the bus this morning and hasn’t taken it off yet!
Fig Jam and Lime Cordial 
Ooh thanks for the detailed instructions Celia! If you do get the time, I’d love a toddler and child sized pattern (but only if you get the time, otherwise I can wing it!). Thank you xx
Done Lisa! It’s now at the end of the post above. If you scale it down even further, you can make a very cute newborn pattern, although best to use thin 100wt fleece for that. :)
Celia, you are a gem! :) xx
Love the beanies! My daughter’s sitting here looking at them and asking if I can make her one! Lol! I would make them in small and medium as well. If it isn’t too hard, I would love the patterns for the toddler and child as well. I have some fleece at home, but it is a dull green. Have to keep my eyes open for some cute prints. I’m thinking ahead for Christmas! Lol! Thanks so much for sharing!
Done Manuela! I’ve uploaded it to the post above. Maybe practice making a big one in dull green for your hubby first! :D
Thanks, Celia! You’re the best! That might be a good idea!
That is great because we WILL have winter once again :)
You always know exactly what I need when I need it Ms Celia. I don’t specifically need a “beanie” but I do need something to line a custom amigurumi crocheted teddy that has an inside chamber and this will work perfectly! You rock Ms Celia and the beanies aren’t bad either! ;)
Fran…”teddy” as in “lingerie”? Ooh, that thought made my eyes go very big.. :D
No, teddy as in “Teddy” bear except a very strange animated one ;)
Its so cold in Sydney today I need Mittens to go with this beanie and a cape of some sort………i may take my donna out with me today …BBBbrrrrrrr
Thanks for the pattern
Thanks for this Celia. It’s so cold in Melbourne at the moment a really warm beanie is a must. My old one is on its’ last legs so you have posted this at just the right time. Thanks again:)
Brilliant!
Brilliant! I knit beanies for charity (I don’t sew) these are so clever Celia.
They look so professional! :)
Thank you so much Celia! Your beanies look so snugly! I just want to wear them on my head, hands and feet – cause it’s so freezing out Penrith way! The Pattern will come in handy as we homeschool (for textile & design) but alas…no sewing machine! Or any room for one either! :(
Celia, they are all so pretty. Do you sell them? Just curiuos.
Not any more Cornelia! Those days are long gone.. :)
What a perfectly cold day to read this post. I haven’t taken my sewing machine out in so long I don’t remember how to thread it. I need lessons!
They must be so warm and snuggly. Perfect for the weather we have here today.
Have a beautiful and happy week Celia.
:-) Mandy xo
Oh this is brilliant – just what I need and all my dog walking pals in Bexhill on Sea for when the weather turns cold (which in reality is today!) again. Gorgeous :) How wonderful that you’ve made so many over the years for such great causes. PS. I finally put the recipe for fideos on the blog x
Darling, I saw!! I haven’t had a chance to comment, sorry, but I did buy pasta in anticipation. I tried tonight but Pete wanted arroz caldoso!! Thank you again for feeding us xxx
He sounds like Big Man – he knows what he likes and tends to stick with it for a long time!
Have a smooth and shiny topped friend due to chemo who might very much appreciate one of these as a gift. Hope I can source some polar fleece, if not I think a pair of pyjama pants may just be re-purposed!
You are a woman of many talents! X
I like the little ribbon trim. You could put one each side and make ears. Sorry, that’s silly because they look very cute just how they are.
Hahaha…no that’s a great idea! Only I think I could make actual fleece ears. Hmmm. Mice or rabbits? :)
Or floppy dog ears like Snoopy.
Those are adorable Celia. I really love the colors you’ve chosen, especially that raspberry color. With the heat wave we’ve been in I don’t think I could work with fleece right about now but you’ve inspired me for fall, that’s for sure.
Thank you for that really handy ‘recipe’. I made the polar fleece sacks for my grandchildren two winters ago; they call them their snuggle sacks. I’m so glad you posted the children’s size pattern. I’m useless at drafting that sort of thing and I wouldn’t have liked to ask – so thank you xxx. Love the picture of your friend in hers, they look so lovely. Young Evan must have looked very cute in his – that’s if his Mum could keep it on him – my children always reached up and sent headwear flying – the flying beanie!
I just LOVE this, the hats are adorable. I feel for you guys, you’re just not prepared for this cold weather, I do hope there isn’t anything really bad happening (frozen and burst pipes). I know I complain when it’s cold in Toronto, but we’re used to it, it happens every year. Our homes are built for it. Although sometimes we do wonder. I’ll be pulling out my sewing machine to make a gift for a friend travelling over the big pond from out your way….you’ll have to stay tuned to find out who! Stay warm.
You are amazing. I can’t believe you’ve made over 500 of these. I think with the cold temps we are having this winter, that a polarfleece beanie is essential. I know you’ve done a very good tutorial but I’m quite sure I would bugger this up – no sewing skills at all xx
you are so clever celia. these are great and i bet they are very warm.
How cute! My boys were eying fleece in the fabric store a while back and come winter I may have to sew some for them. First I need to finally sew my gathering apron before gardening season is gone!
Great idea, I hadn’t realised they were so straightforward to make. Really good step by steps too. It’s still warm here, but being England that could change anytime! GG
Seriously Celia, is there anything you can’t do? Thanks for sharing! Liz xx
I don’t know how to tell a good quality fleece from a bad quality fleece. How do you find out if it is 100 or 200 weight etc? Is it usually written on the bolt? Sorry if the questions sound silly – I am new to sewing with fleece. Thank you for the wonderful tutorial that I just stumbled upon while looking for advice on sewing fleece.
Hi Vicki, sorry it’s taken me a while to answer. I used to buy my fleece online, so it was always identified by weight. If you’re buying it at the store, they should be able to advise you. 100 weight is quite thin, usually used for thermal underwear, 200 weight is the regular thickness most polarfleece sweaters would be made in, 300 weight is very thick and tricky to sew. Hope that helps!