Buzz Lightyear from Toy Story Character Hat Crochet Pattern

Buzz Lightyear from Toy Story Character Hat Crochet Pattern

free character hat crochet pattern from cRAfterChick.com

Buzz Lightyear from Toy Story is such a great character for children to watch. To infinity and beyond! Okay, I admit it. I really like him as well. I decided to see how a character hat of him would turn out for my younger nephew who is a big Toy Story fan as a surprise. It didn’t turn out exactly as I had expected but I do like it.

I would recommend this character hat to advanced beginners and up but if you are new to character hats don’t be discouraged. There are quite a few small pieces that need stitching to be assembled which is why this sat in my works in progress pile for so long. I really hate sewing stuff together. I hope you enjoy this pattern for the Buzz fan in your life and please don’t hesitate to ask me any questions. Happy crafting!

P.S. Just in case you have no idea who this guy is, you can learn more about him here.  Here is the inspiration picture I used to create this hat:

Buzz Lightyear from Toy Story Character Hat Crochet Pattern Notes 

Project requires:
Medium to dark purple yarn for beanie main color
(I use a lot of Red Heart Saver yarn but any medium to normal weight yarn will do)
Light khaki, tan or lightest peach color yarn for face area and nose
Black yarn for eye pupils
White yarn for eye whites
Bright to dark blue yarn for eye color
Dark brown yarn for eyebrows and chin swirl
Bright green yarn for contrast trim
“J” hook (6.0 mm)
Scissors or Yarn Cutter
Blunt large eye yarn / tapestry needle to weave in ends

Abbreviations used in this pattern (US crochet stitches):
ch – chain
st – stitch
sl st – slip stitch
sc – single crochet (US)
dc – double crochet (US)
hdc – half double crochet (US)
dctog- double crochet two stitches together (US)
hdctog – half double crochet two stitches together (smaller sizes only) (US)

Pattern Instructions:

*Note: This project is worked in the round on the base of a magic ring. If you do not know how to do this, please see tutorial here from: yarntomato on CrochetMe

The hat in this picture is made with my free Easy Peasy Youth Sized (Age 3-10 years old) Double Crochet Beanie  Hat Pattern which you can find  here as a foundation for the project. Want it in another size? No worries. Head over to Easy Peasy All Family Sizes Free Double Crochet Beanie Patterns to select the size of the free pattern you want for your project.

Hat Base: in main color purple yarn 

Use Easy Peasy Crochet Beanie Size of your choice Once you have completed your beanie for the base you are ready to transform your beanie into a Buzz Lightyear character hat.

Hat Trim: using bright green yarn

Attach green yarn to where you left of on beanie with a sl st.  Ch 1 before placing 1 sc in 1st st and 1 sc in each of the following st around.  Sl st in the top of the 1st st in round.  Fasten off.

Face Area: using light khaki, tan or lightest peach yarn
Row 1: Ch 18. Place 1 dc in 3rd ch from hook and each of the following 15 ch. Ch 2 and turn. (16 dc)
Rows 2-5: Make 1 dc in 1st st and each of the following 15 st across. Ch 2 and turn. (16 dc)
Row 6: Make 1 dc in 2nd st, skipping 1st st, 1 dc in each of the following 12 st, and dctog last two st in row. Ch 1 and turn. (14 dc)
Row 7: Make 1 sc in 2nd st, skipping 1st st, 1 sc in each of the following 10 st, and sctog last two st in row. Ch 1 and turn.(12 sc)
Row: Make 1 sc in each st to corner, placing 3 sc in corner, continue down side of face area with 1 sc per st to first bottom corner, place 3 sc in corner, 1 sc in each st across to the other bottom corner placing 3 sc in this corner, 1 sc in each st up to the last top corner placing 2 sc in this corner and sl st in top of 1st st worked in row.
Make sure you leave an extra long yarn tail to be able to sew this in place during assembly on to the beanie hat before cutting yarn, pulling through loop and placing to side until needed for face assembly.

This feature works well on toddler, youth, preteen / teen, womens and mens sized hats. If you are making newborn to 12 months sized hats, do the following steps instead of those above that pattern calls for:
Row 1: Ch 14. Place 1 hdc in 3rd ch from hook and each of the following 11 ch. Ch 2 and turn. (12 hdc)
Rows 2-4: Make 1 hdc in 1st st and each of the following 11 st across. Ch 2 and turn. (12 hdc)
Row 5: Make 1 hdc in 2nd st, skipping 1st st, 1 hdc in each of the following 8 st, and hdctog last two st in row. Ch 1 and turn. (10 hdc)
Row 6: Make 1 sc in 2nd st, skipping 1st st, 1 sc in each of the following 6 st, and sctog last two st in row. Ch 1 and turn.(8 sc)
Row 7: Make 1 sc in each st to corner, placing 3 sc in corner, continue down side of face area with 1 sc per st to first bottom corner, place 3 sc in corner, 1 sc in each st across to the other bottom corner placing 3 sc in this corner, 1 sc in each st up to the last top corner placing 2 sc in this corner and sl st in top of 1st st worked in row.
Make sure you leave an extra long yarn tail to be able to sew this in place during assembly on to the beanie hat before cutting yarn, pulling through loop and placing to side until needed for face assembly.

Nose: using light khaki, tan or lightest peach yarn
Round 1: In a magic circle, ch 2 before placing the following stitches in this order: 1 hdc, 4 sc, 1 hdc. Pull circle tightly closed and sl st in top of the 1st st in round. (6 st total)
Round 2: Ch 1 before placing 1 sc in 1st st, 2 sc in the next 4 st, 1 sc in last st and sl st in top of the first st in round. (10 st total)
Round 3: Ch 2 and make 1 hdc in 1st st.
Leave a tail long enough to sew the nose on to the face area during assembly before cutting your yarn. Pull tail through last loop and place to side until needed.

This feature works well on toddler, youth, preteen / teen, womens and mens sized hats. If you are making newborn to 12 months sized hats, skip round 3 of the nose from instructions above.

Eye whites (Make 2): using white yarn
Round 1: In a magic circle, ch 2 before placing the following stitches in this order in m.c.: 2 sc, 1 hdc, 1 dc, 1 hdc, 3 sc, 1 hdc, 1 dc, 1 hdc, 1 sc. Pull circle fully closed and sl st in the top of the 1st st in round. (12 st total)
Round 2: Ch 1 before placing 1 sc in 1st 2 st, 2 sc in next 3 st, 1 sc in next 3 st, 2 sc in next 3 st and 1 sc in remaining st. Sl st in top of the 1st st in round. (18 st total)
Before you cut your yarn, ensure you have left a yarn tail long enough to secure the eye white on to the face area during assembly. Pull through last loop and place to side until steps ask for it.
Repeat steps above for the second eye white.

This feature works well on toddler, youth, preteen / teen, womens and mens sized hats. If you are making newborn to 12 months sized hats, only make Round 1 and skip Round 2 from above instructions.

Eye color (Make 2): using bright to dark blue yarn
Round 1: In a magic circle, ch 1 before placing 6 sc in to the circle. Pull circle closed and sl st in the top of the 1st st in round. (6 sc)
Leave a long enough yarn tail to be able to sew this on place on your eye white during assembly before cutting yarn, pulling through last loop on hook and placing to side.
Repeat above steps for the second eye color piece.

This feature works well on toddler, youth, preteen / teen, womens and mens sized hats. If you are making newborn to 12 months sized hats, make 3 sc in circle instead of 6 sc that pattern calls for above.

Eye pupils (Make 2): using black yarn
Round 1: In a magic circle, ch 1 before placing 2 sc in to the circle. Pull circle closed, ch 1 and sl st in top of the 1st st in round. (2 sc )
Leave a yarn tail long enough to sew the pupil in place on the eye color during assembly before cutting the yarn and pulling through last loop. Place to side until needing.
Repeat process for second eye pupil.

This feature works well on toddler, youth, preteen / teen, womens and mens sized hats. If you are making newborn to 12 months sized hats, skip the instruction above and just make a large knot with a tail to attach it for the eye pupils or ch 3 and sl st in last ch from hook if preferred.

Smile: using black yarn
Smile Main Piece: Make a chain of 7 with black yarn. Leaving a yarn tail long enough to stitch his lopsided smile in place, cut yarn and pull through last loop. Place to side until needed during assembly.

This feature works well on toddler, youth, preteen / teen, womens and mens sized hats. If you are making newborn to 12 months sized hats, make a chain of 5 instead of 7 as pattern calls for above.

Eyebrows (Make 2): using dark brown yarn
Make a chain of 10. Leaving a tail long enough to secure these in place on face during assembly before cutting yarn, pulling through loop and putting to side until steps call for this feature.
Repeat steps for second eyebrow.

This feature works well on toddler, youth, preteen / teen, womens and mens sized hats. If you are making newborn to 12 months sized hats, make a chain of 6 instead of 10 as pattern calls for above.

Chin swirl: using dark brown yarn
For chin swirl, just put to side a small length of your dark brown yarn that was also used for eyebrows to the side. You will be freehand stitching it on face area during assembly. Since I was using a very skinny baby yarn for my darkest brown yarn I made a small chain with a tiny crochet hook to sew it in place.

Instructions are same for smaller sized hats.

Eye Assembly Steps:
The following steps require these face features:
2 – eye pupils
2-  eye colors
2- eye whites

Taking the yarn tail from one eye pupil, use your yarn needle to sew the pupil in place on top of one of the eye colors. You can just center it or make the eyes look in one direction. You can see how I placed mine in my pictures.  Once sewn on, pull yarn to the back of the eye color and fasten off. Repeat process for second pupil.
Now take tail from eye color and using the yarn needle, sew the eye color on to the eye white in desired location.  Once secured in place, pull yarn to the back of the eye white and fasten off.  Repeat process for second eye color.
You now should only have one long white yarn tail from each assembled eye. Do not fasten this off as this is how you will be attaching your eyes to the face area in face area assembly below. If you have any other yarn tails left on eyes that you may have missed during process, fasten them off now.

Face Area Assembly:
The following steps require that you have assembled all the above mentioned pieces. You should have
1- Face Area
2- Assembled eyes
1- Nose
1 – Smile
2- Eyebrows
Small length of yarn for chin swirl

I like to work from the bottom up when doing features so I can judge the space needed for them better so starting off at the bottom of the face area for assembly.
Taking the small amount of dark brown yarn you set aside for the chin swirl, and your yarn needle freehand stitch on a small swirl on the lowest part of the chin area like you can see on picture of Buzz Lightyear above and you can reference my pictures on how I placed them on my hat. Once finished sewing it on, pull yarn to back of the face area and fasten off.
Next take the tail from Buzz Lightyear’s mouth chain and use the yarn needle to sew it in desired place on face area.  I like the off center smile I see in some of his illustrations so that is how I placed mine in the pictures but feel free to do what you like the best.  Once attached, pull yarn to back of the face area and fasten off.
Take tail from his nose and use your yarn needle to sew his nose just above the mouth in a center location of the face area with skinny part on top. You don’t want to attach this too high or it will interfere with your spacing for eyes and eyebrows. Once it is securely in place, pull yarn to the back of face area and fasten off.
Now using your yarn needle, take the tail from one assembled eye from earlier steps and sew it in desired location on one side of nose near top. Once your eyes are fully attached, pull yarn to backside of face area and fasten off. Repeat steps for second assembled eye on opposite side of nose as first.
All that is left now is to add to Buzz Lightyear’s face area is his eyebrows. There is not right or wrong way to shape his eyebrows. If you Google him you will see that he is very expressive with his eyebrows. I personally like his one eyebrow lifted look so I used that as inspiration for my own hat. You can look at pictures above to see how I placed his eyebrows on my character hat. Taking the tail left of one eyebrow chain, use your yarn needle, to stitch the eyebrow over one of the eyes in desired location and shape formation. Once sewn in place, pull yarn to back of face area before fastening off. Repeat process for second eyebrow over other eye.
Now your face area should be fully assembled. There should only be one yarn tail left on this part of your Buzz hat. A long face area colored yarn tail which you will use in following step. If you see any other yarn tails on face area that you may have missed during assembly, go ahead and fasten them off now.

Finishing off:
Now that you have assembled the face area for your Buzz Lightyear hat, take the long yarn tail left on face area from above step and use your yarn needle to sew it in desired location on the front of the beanie hat. I use safety pins or straight pins to pin large features like this in place so I can just sew around without stopping to count stitches or judge space to make sure it’s even. It can take a minute or two at the beginning but saves in the long run. I also find that once I run around the perimeter I do a few little stitches through the middle section of the area I’m attaching to keep it anchored down which prevents the feature from bubbling up.
Once you have fully sewn the face area on, pull your leftover yarn tail to the inside of the beanie hat before fastening off.
Double check your work now for any extra tails or loose ends you might of missed. Fasten any off if any are found.
All done! One super cute Buzz Lightyear crochet character hat ready to wear.

Here are some pictures taken to show how Buzz Lightyear hat looks once all done:

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