This idea came to me one night while I was trying to sleep-most of my ideas come then. But they aren't always good ideas :) I think this one might be though. I thought it would be perfect for a baby because it's not very tight. I'm always worried about those little elastic headbands squishing tender little baby heads. All you need are the following:
1. an old T-shirt
2. sewing machine, thread, etc. . .
3. 1/8" elastic
1. Cut off the bottom hem of the T-shirt.
2. Cut a 1-3/4" strip off the bottom of the T-shirt-this is your headband.
3. Starting an inch from one of the seams, pinch the jersey material.
4. Fold the "pinch" forward an inch. (no rhyme intended).
5. The T-shirt side seam should now be on the bottom (as shown), and you have a nice little one inch fold. Pin in place.
6. Continue measuring and inch forward, pinching it and pulling it forward another inch and pinning them. Do this until you have enough to make your headband the desired circumference. (A newborn's head is usually around 17"). If you're measuring it laying flat remember it's doubled over-so you need to double the number to get your circumference.
7. Baste through the center of all your folds.
8. Cut a piece of 1/8" elastic an inch shorter than the total number of all your folds (So if you have 5 folds cut a 4" piece of elastic, if you have 7 folds cut a 6" piece of elastic.) Center it at the end of your folds and start sewing, back stitch. AFTER you've backstitched pull the elastic while you sew it down the middle. Pull it so it reaches all the way to the end of the last fold. It's kind of tricky to pull it, make sure it stays down the center and sew through the elastic all at the same time. Take your time.
When you're finished sew a simple button on the end-or two. Make sure you sew it securely (I have fears of babies choking on buttons too).
You now have a ruffled headband. Model it on a patient little buddy: