A pattern I've had my eye on for a long time, but never got around to making, was the Dwarven Battle Bonnet and Dwarven Battle Bonnet 2 by Sally Pointer of Wales. These are super fun to make and wear, not to mention being immensely practical, essentially balaclavas with style and whimsy. I never imagined my husband would be interested, but I'd never shown the pattern to him until he mentioned the bike ride across Manhattan was getting kinda nippy now that winter was closing in. To my surprise, he was very excited for me to make him one. Then when I mentioned it to my SIL she said that my nephew would really want one as well. Fortunately it is a very fun pattern that I was more than happy to make a second time, and both of them came out quite well.
My husband has a giant head, so I actually had to make his a larger size than provided for in the pattern. I added a bunch of stitches and kind of winged the eye and mouth holes to go along with the increased number of sts. Here it is in progress:
It turned out the eye holes were too large the way I knit them, and I ended up later crocheting around the outer edges to fill in some of the space. He wanted it knit with black hair and beard (despite clearly having a brown beard as you can see).
Ultimately, I think it came out well, and he was delighted with it.
My nephew is a normal sized ten year old, so I made the child's size for him and it fit him fine, with room to grow.
Here he and my husband are together on Christmas Eve, posing together with their matching helmets.
One for my niece is on the way. She has requested blue tips on the hair and beard!