Handmade Halloween: Policeman Hat Pattern and Tutorial from Boy, Oh Boy, Oh Boy!

Hi Rae Gun Wears readers! I’m Stacey and I blog over at Boy, Oh Boy, Oh Boy!  I write about sewing, crafting, and keeping my three very energetic boys busy.  I’m very excited to be here today for Marissa’s Handmade Costume series.

When it comes to Halloween costumes, I like easy.  With three boys running around the house and three very different ideas of what makes a fun Halloween costume, not to mention that they tend to change their minds at the last minute, I’m not about to go crazy on something that they’ll only wear once.  Which is why I was so excited when the boys decided to go with something traditional.
Kid's Police Hat Pattern

If you are looking for a last minute costume, you’re in luck.  What’s easier to put together than a policeman costume?

Grab a blue button down shirt and blue pants, a few dollar store accessories and all you have to make is the hat.  Here’s how:

What you need:

1/2 yd. navy blue quilting cotton + scrap of black for brim (optional)
scrap of clear vinyl
scrap of heavy weight interfacing
coordinating thread
plastic police badge

Print the hat pattern (the large size will fit 5-7 yrs, the small size fits 2T-4T). Tape pattern pieces where indicated.

Cut your pattern pieces, making sure to lay your material on the fold when indicated.  Use a 1/2″ seam allowance unless otherwise indicated.

Fold the headband in half, short raw edges (right sides together).  Sew along the short raw edge to form a loop.  Repeat for the other headband piece.

Pin the lining headband and lining crown pieces together (right sides together) lining up the headband seam with the back of the hat. Sew.

Repeat for the main fabric pieces.  Press the seam toward the band and top stitch along the top.

With right sides together, sew the navy blue brim pieces together along the outer edge.

Clip the curve and turn right side out. Repeat for the clear vinyl pieces making sure to lay a piece of tissue paper or stabilizer between the vinyl and needle.

Insert  the navy blue brim inside the clear vinyl brim and pin the brim to the right side or the outer hat, opposite the seam in the back.  Sew the brim to the headband.

Place the lining hat inside the outer hat, right sides together.  Make sure the brim is turned so it is sandwiched between the layers.

Pin and sew around the raw edges of the head bands, leaving a 2 to 3 inch space, hear the brim, for turning.

Before turning:  Try hat on your child.  If the hat is big follow the next step.  If not skip ahead.

Cut a piece of elastic.  Small size:  2 1/2 ” piece of 1/2 wide elastic  Large size:  3 ” piece of 1/2 wide elastic.

Pin elastic onto the seam allowance at the bottom of the hat straddling the back seam.  Using a zig zag stitch sew the elastic stretching as you sew and back stitching on each end.  Make sure you only sew on the seam allowance, otherwise it will cause problems for turning.

Turn the hat right side out.  Press all seams, turning the open ends in toward each other. Pin the opening and then top stitch all the way around the bottom of the hat band.  Stretch the elastic as you sew.

Glue or sew the police badge to the front.

Printable Police Hat Pattern

And there you have it.  An instant, handmade, police hat.  Which is all you need to get into character.  And the best part about this Halloween costume?  Once the spooky fun is done, the hat is sure to get used over and over again during imaginative play.

If you’re looking for more fun, handmade dress up ideas, pop on over to Boy, Oh Boy, Oh Boy! We’ve got ninjas, superheros, and knights galore.  And if you do, don’t forget to say hi and let me know you came over from Rae Gun Wears.  Thanks for having me today, Marissa!

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  1. Oh my! Such cute costumes I can hardly stand it. Sometimes I wish I had more than one kid so I could theme their costumes!

  2. Thank you, Debra. I love the family theme costume idea. I’m not sure how much time I have left to keep the costumes themed but I’m milking it for all it’s worth. There are tons of great family theme ideas for families of three so if mom and dad are willing, there are endless possibilities.

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