How to Make a Pilot’s Hat

Top off your little pilot’s aviation ensemble with this simple cap made from old winter gear.


  • Old winter hat, plain color
  • Scissors
  • Hot glue gun (with parental supervision)
  • 2 buttons


  1. Cut two slits about 4 inches apart up the front of the hat. The top of the slits should be about 3 inches from the hat’s top edge.
  2. Trim the flap that you’ve created to about 2 ½ inches in length. Fold it in half upwards and secure with glue.
  3. Attach two buttons onto the upturned flap, one near each corner as shown.
  4. Flip the cap over and trim off excess fabric to so that you’re left with a rounded ear flap on each side.