How to Make a Rocky Plush from Project Hail Mary

I sourced the patterns from this TikTok and added directions to the patterns I drew up. Throughout this project, I want you to approach every task with the mindset of Eva Stratt: we’re here to save the world. Prioritise progress over perfection. Focus on delivering effective solutions quickly, making decisions with confidence, and getting the work done rather than chasing flawless results.

Tools:

Hand sewing needle
Sewing Machine
Fabric scissors
Paper scissors
Craft glue
A finely sharpened piece of soap
Scalpel blade
Cutting mat
Pins

Materials:

Dark brown felt
Brown felt
Brown thread
Green felt
Blue Vinyl
Brown thread
Silver embroidery thread
Brown embroidery thread
Polyester fill
Pattern

Pattern: (Adjust for your own personal use)

Rocky Pattern

Step One. Pattern

Print out the pattern. Cut out pattern with your paper scissors. Cut the notches.

Step Two. Marking & Cutting

Lay the pattern pieces onto your base fabric, which in this case is the brown fabric. Trace around each piece with soap, or pin the pattern directly to the fabric and cut each piece out as you go. I chose to trace the pieces first so I could save fabric and make the most of the material.

I have included grain lines on the pattern pieces. However, because I am using felt, which is a non-woven material, you can ignore these lines if you are using the same fabric.

Use a scalpel blade to carefully cut around the curved lines, as this will give you more control. For the larger pieces, you can use fabric scissors instead.

Step Three. Sewing Upper & Lower Legs

Take two lower limb pieces and match the notches together. Sew the pieces together using brown thread, or a thread colour that matches your chosen fabric. Repeat this process with the remaining lower limb pieces until you have four completed lower limbs.

Next, take two upper limb pieces and match the notches together. Sew the pieces together, following the shape of the pattern. When sewing around the curves, keep the needle down and gently pivot the fabric so the seam stays smooth and accurate. Repeat this process for the remaining upper limb pieces.

My seam allowance is 0.3 cm. Remember to trim any loose threads as you go.

Step Four. Sewing The Side Pieces & the Under Body

Sew four of the five side pieces together, matching the notches as you go. Leave the space for the fifth side piece open.

To make it easier to add the fifth side piece later, begin sewing from the notch lines, or about 0.5 cm in from the seam allowance, rather than right at the edge.

Next, sew the underbody piece to the joined side pieces. At each point or corner, keep the needle down, lift the presser foot, and gently turn the fabric so the edges line up neatly. Continue sewing this way all the way around.

Once the underbody is attached, sew in the fifth side piece and close the bottom seam completely.

Step Five. Sewing the Top and the Sides

Sew the top body piece to the side pieces using the same method you used to attach the underbody piece. Match the edges carefully as you sew, keeping the needle down at each point or corner so you can turn the fabric neatly.

Remember, the seam allowance is 0.3 cm. Cut away loose threads as you go.

Leave the right side at the back of the plush open.

Using the same technique from Step Four, sew the underbody piece to the side pieces. When you reach each point or corner, keep the needle down, lift the presser foot, and gently turn the fabric so the edges line up neatly. Continue sewing all the way around, making sure the pieces stay matched as you go.

Step Six. Inside Out

Turn all the pieces right side out. To help open them up, gently insert closed scissors into the openings and carefully widen the seams.

If you tend to be a little rough with your tools, use a popsicle stick instead. This will help push the pieces into shape without accidentally damaging the fabric or seams.

Step Seven. Embellishments

Add your embroidery embellishments at this stage. If you need a guide for creating a specific image or design, I suggest lightly drawing it onto the fabric with soap first

For this part, I’m using machine embroidery thread with a regular sewing needle. The needle brand I use is Milwards Needles. I’ve chosen machine embroidery thread instead of standard embroidery thread because it gives the finished piece the look I’m hoping to achieve.

Remember to begin stitching from the inside so your knots are hidden.

If you are sewing straight across, as shown in the pictures above, be careful not to pull the stitches too tightly against the fabric. You still need to add the polyester fill, so leave enough room for the fabric to hold its shape once stuffed.

I did not use any particularly unusual stitches here, except for a stem stitch on the mark on Rocky’s right upper leg.

Rocky has a variety of markings and I’ve only elected to do the most important marks. The silvery mark on the left of the upper limb. Lines on the lower limbs. The mark on the right upper limb.

I’m not going to put on the green flakes or Adrian’s mark on just yet at this point as I want to stick them on with craft glue but if you want to hand sew them on I suggest a stem stitch or a back stitch. Remember to secure the stitches on the inside of the fabric when tying off and cut away loose threads.

Step Eight. Stuffing

Stuff each plush piece with polyester fill. Break the fill into small pieces before adding it, as this will help create a smoother and more even shape.

Use a popsicle stick to gently push the filling into the bottoms and smaller areas of each piece, making sure the shape is fully filled out without overstuffing.

Don’t overstuff the pieces and make sure you leave enough room to sew up the body and the limbs.

Step Nine. Armband

To sew the armband first take the measurement of Rocky’s upper arm, add 0.3cm for ease. Cut the fabric. There isn’t going to be a clunky seam here, we do this putting the end of the seams together by using the hand sewing technique back stitch. Prepare your embroidery thread, then begin stitching from the back of the fabric, bringing the needle through to the front. Push the needle back down where the first stitch ends, then bring it up again a short distance ahead. Continue this process all the way around, creating as many rows of embroidery as you would like.

If you only create one line of embroidery, make sure the seam is secured all the way down. I recommend using backstitch for this. Once finished, tie off the thread at the back of the fabric and trim away any loose ends.

Step Ten. Invisible Stitching

Insert the needle from the inside of the opening in the seam allowance and bring it out through the edge of the fabric. Sew across to the opposite side, picking up only a small amount of fabric, then return to the original side close to where the thread first came out. Continue this process, alternating from side to side, until the opening is closed.

Once the hole is fully stitched, tie off the thread and trim the excess. Use the needle to push the thread tail back into the body of your work so it is hidden.

Step Eleven.

Cut the green felt, put craft glue on one side and decorate your plush. Here if you decide to use vinyl for Adrian’s mark like I did you would also do this here.

Step Twelve.

Taking the instructions from step nine invisible stitch the limbs to the body at the red notch points.

Use this invisible stitch to close the body, lower limbs, and upper limbs but instead of going once across I suggest twice one around for each side. At this point, I would also attach Rocky’s armband.