Download the template, edit it in Adobe Reader to add your child's name, print it, and cut out the pieces you need.
Begin by gluing the white stripes to the hat.
Glue the blue band along the bottom of the hat.
Next, glue the star in the center of the blue band on the hat.
Place the face piece in the middle and to the top of the beard piece.
Now, glue the eyes below the eyebrows.
Position the nose between the eyes and above the mouth and glue it in place.
Glue the completed hat to the top of Uncle Sam's head.
Next, glue the beard letter pieces to the back and bottom of the beard so it spells out the name.
Finish off by slightly curling the bottom of the beard letter peices to give them a 3D look.