Here's my cute little guy dressed all warmly!
I started with a women's size small fleece pajama shirt.
Fold the shirt so that the side seams are on top of each other.
Match the front of the pattern piece to the fold so you're not cutting the first few inches. (So you are going to have two hat pieces that are connected in the middle.) You can then do one of two things. 1. You can start sewing where the fold ends, all the way up and over the curve of the hat, stopping before the pattern curves down to make the ear cover piece.
Then finish the edge around the ear, or you could cut the pattern out twice and sew it together, (right sides together, then turn inside out) making a warmer, thicker hat. It will look like this (the one layer version):
2. Or, if you want to make a more square shaped top, with tassels coming out of the corners, when you cut out the hat, you need to leave a square shape like this (see below) instead of a curve. The difference is marked on the pattern piece. You will still sew up the side opposite the fold, but leave the top open for now.
Make the tassels by using scraps (you need the scraps to be around four inches or so wide, and two to three inches long) from the bottom of the fleece shirt, and cutting strips about 5/8 inch wide.
Roll up the fabric, and sew in place. Then, with the main hat piece still inside out, match the seam you already sewed (the very back of the hat) to the fold that is the very front of the hat, and pin. Then put the tassels in the corners, with the tassels pointing inside, so that when you turn it right side out, the tassels will be on the outside.
Finish any way you like. You can leave the raw edges, since the fleece won't fray, but if you want to make it a little more sturdy, you can 1. sew 1/4 inch or so from the edge, 2. fold the edges under and sew, or 3. make two hat patterns (omit the tassels on the second one) and sew them together (again, with right sides together leaving some room to turn inside out, then sew up the hole) for a warmer, thicker hat. You could even add straps or tassels under the ear.
There is still so much fabric to be used from the fleece shirt! Try making some tiny mittens from the sleeves!
Cut about six inches or so above the sleeve cuff.
Cut a rough mitten shape- doesn't have to be perfect. Sew all around the curves of the mittens.
Cut a piece of elastic around four inches long (you may have to adjust that to fit your toddler) and sew the ends together. With the mittens turned inside out, put the elastic around the mitten, about 2 or 2 1/2 inches up from the edge, and pin in place, stretching the elastic so that the mitten is bunched evenly all the way around. Zig zag stitch the elastic all around the mittens, then turn right side out.
Mittens!
Finally, I had enough fleece left to sew 2 pieces together to make a little scarf. It can be as easy as cutting a rectangle from the fleece and cutting tassels at the end- no sewing necessary.
