Baby Zuma PAW Patrol Costume DIY * Moms and Crafters

I made this no-sew Baby Zuma PAW Patrol Costume as part of our PAW Patrol inspired family costume! I chose Zuma for Baby Y because I wanted something comfortable and wearable for a baby. Since Zuma wears a helmet with a strap, I figured I can replicate that with an ear flap hat. Disclosure: this post contains affiliate links.

To make this Baby Zuma PAW Patrol Costume, I half-used a pattern – just to get the cap of the hat right. The size was slightly large – with the perk being that M can now wear it when he plays “PAW Patrol” with his friends.

This DOES require a teensy bit of understanding how sewing works – even if you’re not sewing, but if you want to make it easier, you can just work with an orange trapper hat or helmet – just pin/tape things on temporarily instead of gluing so you can use it afterward!

I had to redo the vest twice (!) Because I accidentally measured with a skin-tight romper, and it was too small for that pudgy belly. Make sure you use a loose-fitting shirt to measure the size of the vest.

Just like I did with our previous DIY PAW Patrol costumes, I did not sew it. I glued these together using Fabri-Tac, creating seams as you would with any sewing project. Of course, if you prefer, you can sew it.

The boys had so much fun wearing these easy DIY costumes, and of course, to this day, the nickname “Zuma” stuck with Baby Y.

What you need to make a Baby Zuma PAW Patrol Costume:

This pattern
Orange fleece
Fabric glue
Brown felt + a strip of royal blue soft felt
Fabric scissors
This template and these printable badges (print and cardstock and laminate with packing tape)
Hook and loop closure
Mod Podge and a foam brush
A bit of string

How to make a Baby Zuma PAW Patrol Costume:

Make the Baby Zuma Paw Patrol Costume Hat:

1. Use the pattern to cut out two of the pieces labeled “side hat pieces” from orange fleece.

2. On that piece of the pattern it tells you to also cut a strip. Follow that instruction too. If you are making a baby hat (not a toddler, as the pattern states) you may want to measure with an existing hat of your baby’s to make sure the sizes are matching up (make sure to allow 1/4 inch seam allowance).

3. Start gluing the arch of the sides of the hat to the long side of the strip. Your good sides should be facing each other.

Continue along the curve until you have completed the curve.

And repeat it on the other side of the strip with your other “hat side”.

4. Flip your hat inside out. You now have the cap of your hat!

5. Because the hat pattern was too big, I did not use the pattern to create the flaps – I just made my own. You definitely can use the pattern if you’d like, if it’s the right size. I just created two flaps in the size I wanted to and glued them on.