This little project I did a couple weeks ago, but wanted to document it here. My parents went to Disneyland this summer and bought my boys some pirate swords. They came with eye patches, but we needed a pirate hat.
I got the general shape and traced the scull from the pattern here.
I made it out of felt, and just drew the inside of the face with a fabric marker. Instead of doing Velcro closures, I put elastic in the back. That way it can stretch to fit either of my boys' heads.
If you are looking for a Halloween costume, these was a really easy, quick hat to make!