How to make an Undertale Sans Hat

Do you know or are you an Undertale fan?  Do you want to dress up for Halloween as Sans from Undertale?  We have a simple way to make a great Sans costume!  We also have a Temmie costume tutorial, so click over to find out how to make one.

Take an inexpensive white knit hat and sew eyes, nose and toothy grin like Sans from Undertale onto the hat.   Wear black pants, a black or dark-colored hoodie with stripes on the sleeve and black gloves to finish the look.

Watch our video or keep reading for step-by-step instructions to make the Undertale Sans hat.

INSTRUCTIONS

STEP 1: DOWNLOAD TEMPLATE

Download the template for the eyes, nose, and mouth from the link near the end of this post.  Print out the template so you can use it to cut out the pieces from the felt.

STEP 2: CUT OUT PIECES

From your template, cut out the different pieces for the eyes, nose, mouth, and teeth.  The mouth, eyes and nose template, will be cut out of black felt.  The pupil and the teeth pieces will be cut out of white felt.  The template pieces have written on them the number of pieces to cut out.

From Black Felt cut:

• Eyes - cut 2
• Nose - cut 1
• Mouth - cut 1

From White Felt cut:

• Pupil - cut 2
• Teeth - cut 2 of each of the 3 tooth pieces.  You will have 6 teeth.

To cut out the templates, lay each template on the felt and pin it to the felt.  Carefully cut around each piece.

Lay the pieces out like shown in the photo above.  This will ensure that all of the pieces have been cut out and they will fit correctly together.

STEP 3: STITCH THE PIECES TOGETHER

Using your sewing machine, zig-zag stitch the pupil to the eye pieces.  Also, zig-zag stitch around each tooth to attach them to the mouth piece.

You can also stitch the pieces together by hand if you do not have a sewing machine.  

STEP 4: STITCH ONTO HAT

Place the eyes, nose and mouth pieces to the hat where they will look the best.  Pin the pieces to the hat to hold them in place.

Next, using your sewing machine and a zig-zag stitch, stitch around each of the pieces to attach them to the hat.

As before, you can stitch them to the hat by hand sewing them.  It will take a bit more time, but you can still make this hat without a sewing machine.

The hat is complete! 

STEP 5: REMAINDER OF COSTUME

To finish out the Undertale Sans Costume, wear black shorts, a black or dark-colored zip-up hoodie with a t-shirt underneath, black gloves and the hat.  It's the perfect Sans costume!

Look below for suggestions of products to purchase to finish out your costume.  The best thing about these is you can wear them after Halloween as regular clothes.

Below is a photo of my kids in their Undertale Sans and Temmie Costumes.

 

Did you like this project?  Look for many other kids craft videos by clicking the link.

We also have a video and step-by-step tutorial on how to make an Undertale Temmie costume.  

Undertale Temmie Costume