I'm basing these projects on this version of the fleece pussyhat. I was really happy with my results, but since I bought a yard (36 inches) of fabric, and the pieces for the hats are designed to be 20 inches long, that left me with a weird strip of leftover fabric, about 60 inches wide and 15 inches long. I always seem to lose at least an inch of fabric to the piece not being completely square, or because I sometimes cut too deep as I'm cutting, and I'm ok with that.
But I'm not really ok with that much waste. Anti-pill fleece isn't expensive, but it is 100% polyester, which doesn't biodegrade, and while it's not like I'm composting my cotton scraps, it bothers me a bit whenever I waste anything, but especially a synthetic fabric.
I thought I'd try making a version of the hat with a cuff. I tried one where I only cut 11" pieces for the main part of the hat, and it came out really small, so I'm going to go ahead and suggest that 12" might be better. Test for yourself. The original pattern doesn't specify a seam allowance, so maybe she was working at a quarter inch, while I prefer a half inch, and that would make her finished hat an inch larger around than mine, which is quite a difference when it comes to hats.
There's another reason to check your sizing before you cut out as many of these as possible - the cuffed edge seems to make the hat fit a little more snugly than the turned-and-stitched hem. That could be because of something I'm doing wrong, or it could be inherently less stretchy. I'm not sure. There are two lines of stitching instead of one, and maybe that is enough to make a difference.
This is how I did it. Cut one piece of fleece that is 12 inches wide and 15 inches long. This is the main hat. Cut another piece of fleece that is 23 inches wide and 4 inches long. This is for the cuff.
Once you have your sizing figured out, you can cut several hats at once from your theoretical scrap above: cut one piece that is 23 inches wide and then cut three 4-inch-long pieces from that. That leaves you with a piece that can be cut into 3 pieces for the main parts of hats. If your fleece turns out to be 59 inches wide when you trim the selvedges, you can always cheat a little bit and cut the main hats at, say, 11 and a half inches, then work with a smaller seam allowance. Or make two hats that are the size you want and a third that's a bit smaller, that may fit a child. You'll have to adjust the seam allowance for the cuff on the smaller hat, so that it will still fit nicely together.
Sew the side seams of the hats and sew the ends of the cuffs together so that they form a circle. Fold the cuffs, wrong sides together.
Pin or clip the cuffs to the hats, right sides together, lining up all raw edges with each other. Stitch with a half-inch seam. This makes for a really bulky seam, with three layers of fleece together, so go slowly and consider using a walking foot, if you have one. I don't have a free arm on my sewing machine, so I like to stitch anything to do with the hem or cuff from the inside of the work, as in this example and this one. You can serge this edge, too, but I would baste it on the sewing machine first, because it's so much bulk.
Flip the cuff down and look at which two seam allowances will be covered by the third one when the hat is worn. Trim the two that will be covered, to reduce bulk at the seam. Topstitch the cuff in place, using a stitch that stretches, like a zigzag or a three-step zigzag, if you feel fancy. Finish the "ears" of the hat by topstitching with a straight stitch.
I know I'm repeating myself, but when you are finished, clean your machine, even if you don't usually clean up after every project. Fleece tends to shed a bit and it can gum up your machine worse than most other fabrics.
More ideas for fleece scraps:
- piece them together and make a pet bed. Even if you don't have a pet, most shelters will accept beds/ blankets for their animals. Check with your local shelter before you sew!
- cut them into smaller strips/pieces and use them to stuff everything from pet beds to dolls.
- find a pattern that doesn't take a lot of yardage. Mittens and hats, especially for kids, are often really low-yardage. Again, just because you don't have a kid doesn't mean you can't sew for them. Check with a local charity to see what's needed.
- stuff them into a bag and feel guilty. This is my most common response to scraps, but it's not very fulfilling.