DIY Sew an Elmo Sun Hat

This might not be the most thorough tutorial, but I wanted to post it just to give readers an idea of what I did.  To make a normal reversible sun hat, I found a tutorial on another blog.  (Sorry, I searched for awhile and I cannot remember which one it was!)  I picked Sesame Street fabric for one side and plain red fabric for the other side so I could add the Elmo face.  

Before I completely sewed the entire hat together, I started working on the Elmo face so I could make sure it fit on the hat.  I printed out a picture of his face that was resized to fit the hat.

I used some little scraps of fabric for the eyes, nose and mouth and two black buttons for the eyes.

Using my printout as a guide, I cut out the face shapes and ironed some fusible interfacing on the back to make them a little more stiff.  I sewed the buttons onto the eyes by hand and then used the machine to do the rest.

I carefully pinned the face pieces onto the hat and then used a zig-zag stitch to embroider them onto the hat.  Unfortunately, my sewing machine had a mind of its own that day, so the stitches don't look as nice as I wanted them to.

Here he is showing off the Elmo face on one side...

And the Sesame Street print on the other...

I love how it turned out and it's great to have two different hats in one!