How to Make a Kitty Hat (for Humans)comments (22) October 15th, 2014
First, you need to cut out your rectangular hat shape. Decide how wide your hat should be-I wanted my hat to be extra wide so it would flop down on the sides, so I cut it about 12 inches wide for my 22-inch head. You'll get kitty ears from the rectangle-shaped hat whether or not it's extra wide. Remember seam allowance, and if you want a more fitted hat, then cut it a little less than your head size divided in half. And for the height, I cut it about 7 inches high, but if you're not making yours extra wide, then you should make it higher by an inch or two. One side seam of the sweater will be a side seam on the hat, so with the sweater lying flat, just cut through both layers straight up for the other side and straight across the top. You can always cut in more, so if you're not sure how big to cut it, try bigger than you think is good, hold it around your head, and trim more where needed.
Now turn it so the right sides are facing, and sew up the side and top using a zigzag stitch. Try not to stretch it at all while sewing-the more it's stretched, the more it'll ruffle!
You can leave it at that, or you can sew back over all the seams for extra security and neatness. Turn the hat right side out, open it up, and sew right on top of the seams with a zigzag stitch, so it zigzags from one side of the seam to the other side.
It's a bit tricky going over the pointy ear parts, but if you go slowly and stretch out the fabric at the ears, you can sew from the side to the top and back down the other side without stopping.
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