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About the designer

I run a blog about steampunk costuming at as well as a seamstress and corsetmaking business.

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Aviator Hat

from Steam Ingenious
(9) Name: 'Sewing : Aviator Hat
Aviator Hat
Aviator Hat

Basic Skills Necessary:

  • Basic sewing
  • sewing leather or vinyl
  • sewing very curved seams

Pattern Description:

This intermediate level sewing pattern is for a WWI or WWII styled aviator's hat. The pattern is multi-sized, including Small (19-21" head circumference) , Medium (22-23"), and Large (23"-24"). The pattern is designed for use with real or faux leather, although you can use any fabric you like. It includes optional decorative details such as two styles of ear coverings and optional straps.

This pattern is s little more challenging than the other sewing patterns I sell, due to the extreme curve of the seams, and therefore is recommended for a sewer with some experience. A total beginner may have trouble with the curved seams. Using real or faux leather also adds some difficulty. The pattern includes two PDF files: one PDF with step-by-step instructions and full color photos of each step, and one of the pattern itself. The pattern is designed to be printed easily on any home printer.

This hat will be perfect for any dieselpunk, airship pirate, WWI, or WWII aviator costume. With the ability to make it to perfectly fit your head in whatever fabric you want, the possibilities are endless!

Sizing / Finished Measurements:

  • Small 19-21" head circumference
  • Medium 22-23"
  • Large 23-24"


  • 1/2 yard leather or faux leather or other fabric
  • 1 3/4" buckle