making your own hat is so satisfying, you’ll wonder why you never made one before. easy as pie!
Materials:
- 1/2 yard hat fabric
- 1/2 yard lining fabric
- 1/4 yard fusible interfacing
- button
- sewing machine/needle & thread
- (optional) ham for pressing
Instructions:
1. lay out the pattern pieces
2. pin the pattern pieces to your fabric
3. cut out all the pieces (in hat & lining fabric) and interfacing
4. on the side pieces, mark the edge closest to the front pieces (this edge is longer and helps with the shape of the hat)
5. fuse interfacing to the peak pieces
6. with right sides together, sew the back pieces together at 1/2″
7. with right sides together, sew the front pieces together at 1/2″. then sew the side pieces to the front piece
8. press the seams open now (it will be harder to press later, when the hat is assembled)
9. sew the back piece to the sides
at this point, you can trim some of the bulk off the top.
10. repeat steps 6-9 for the lining fabric.
11. with right sides together, sew the peak pieces together at 1/4″
turn the peak right side out and press it flat.
12. you should now have 3 pieces that look like this
13. (optional) topstitch the peak at 1/4″ for decoration.
14. with right sides together, pin the peak to the hat
15. lay the hat and peak into the lining (which is inside out)
16. beginning at centre back, sew the hat to the lining at 1/4″, leaving a 2-3″ gap
17. turn the hat right side out
18. press the edge of the hat flat
(please excuse the dirty laundry in the background)
19. blindstitch or machine stitch the opening closed.
20. attach a button to the top of the hat, sewing through both hat & lining (so that the lining doesn’t fall down)
21. ooooh
* another way of finishing the hat is to leave the raw edges of the hat and lining exposed
and stitch a grosgrain ribbon over them.

62 Comments
September 18, 2006 at 12:31 am
Is there a pattern or did you use a specific pattern otherwise it makes this millinery piece a bit hard to reproduce.
September 18, 2006 at 4:10 pm
the finished hat looks gorgeous, thank you for sharing this tutorial! how did you go about sizing, is there some math about about it?
September 18, 2006 at 8:38 pm
hey ladies! yep i used a pattern which makes a hat to fit a head with a 22.5″ circumference (the most common). the seams could definitely be adjusted to accomodate a bigger/smaller noggin.
September 19, 2006 at 10:59 am
What a great tutorial. Have linked to this post from my site.
Mia
September 19, 2006 at 5:18 pm
I’ve made caps very similar to this one, with a larger brim; mine are a little smaller cap, as in baseball cap. See my website, http://www.acsalaska.net/~edie53/crazyquilts/cap/baseballcap.html, and my blog, http://cowgirl53.wordpress.com/2006/09/14/new-hat/ for photos. It does look good in stripes, and they’re fun to manipulate. LOTS of things you can do with this hat!
September 20, 2006 at 11:20 am
great idea – very cute hat – is there a pattern you used? or do you suggest just winging it from the picture?
September 20, 2006 at 11:31 am
This looks fab! I would love to buy this pattern… can you tell us where we can get it?
October 8, 2006 at 1:27 pm
i love that hat!!! my church is/has been doing chemo hats for our local hospital; which many of us are doing; also my sister-in-law is going through chemo and i am doing hats for her. Where could I get that pattern! Thanks so much!!!
December 3, 2006 at 12:08 pm
Just found this tutorial via Tania. Wonderful. Thank you!
December 20, 2006 at 3:37 pm
It is possible to draft a pattern yourself if you have a little patience. Measure the circumferance of your head just above the ears, where the hat would end. Add maybe half an inch or 1/4 inch for fabric bulk. Measure from your circumferance line up to the top center of your head, where the top of the hat would be. Add about half an inch or 1/4 inch for fabric bulk. Then you take your paper, and draw a vertical line that is as long as the second measurement. Take the first measurement, and divide it by the number of sections, looks like six here. Take that section number and draw a horizontal line at the bottom of the first line on your paper. Then start at the top and draw a shape like in the picture, on one side. All around the outside, draw your seam allowance. Cut the thing out and fold it in middle, and cut the outside edge to make both halves the same. Then copy the other sections from it. Tape it together with tape and see if it fits- if it doesn’t, start over and keep trying. You can use an old sheet from the thrift store or something to draft this up too if you want. When you get the cap right, draw yourself a bill, adjust as necessary, and there you go. Remember if you have it too big, you can add a couple inches of elastic in the back inside, stitch it down. If you have it too small, you can give it to a child.
December 20, 2006 at 3:40 pm
Don’t forget to make one out of some adorable fabric and add animal ears and a wee little nose and eyes
December 20, 2006 at 3:42 pm
Oh wow, then I see at the top that the pattern is RIGHT THERE- Duh- LOL
December 22, 2006 at 1:18 pm
That looks fantastic! I love it. Thank You for posting the pattern, you rock! It’s actually just what I needed, my sister will be getting one for Christmas. Thanks Again!
January 19, 2007 at 7:21 am
Very cute … nicely done!
~firefly
January 22, 2007 at 4:24 pm
i love it. this is great for “i want to hide my terrible hair” days. thanxs so much for sharing.
March 2, 2007 at 8:19 am
I’ve always wanted to make hats but there aren’t really any milinery schools in South Africa. Thanks for the pattern!
March 8, 2007 at 9:56 am
Just finished making a hat from your pattern. Put it up on flickr with some comments. This is the BEST hat pattern ever. The fine detailing by shaping the crown pieces is brilliant.
http://www.flickr.com/photos/glorioushats/414577702/
Will get an article about it on my blog too. Thanks so much and so glad a friend wisted your hat.
August 30, 2007 at 9:19 am
I am definitely trying this. Thanks for the tutorial!!!
September 5, 2007 at 10:03 pm
I just made it too!
Cool pattern!
October 8, 2007 at 1:43 am
Probably a stupid question, but I really don’t understand how the brim is attached… Did you turn the hat inside out again when you put it against the lining?Did you pull the brim through the gap you left?
October 12, 2007 at 12:32 pm
Sew the pieces crown pieces all together, after that sew all of your brim pieces separately, make a small notch
in the center of the brim so that you will know theat the center front of the brim should match to the front center seam of the hat sew the brim raw edge to raw edge of the crown and then sew in your lining. I hope this helps!
November 27, 2007 at 12:06 pm
This hat is awesome! I’ve been making welding hats for my husband and have been wanting to make myself (a feminine) hat. Thank you so much for this tutorial! I’ll have to give this a try!
November 27, 2007 at 12:23 pm
Great hat! I put a link to it from my blog so that I will remember to make one!
http://mylittlesewing.blogspot.com/
November 28, 2007 at 9:30 am
Hi, I have decorated an ordinary ladies straw hat to look Victorian. Thing is i need to line it now but not sure as to how to do this. I did think of a piece of material circle shape and then over lap it inside to fit and to sew at the top to keep it in place. Hope you can help ?? Sharon , Horsham, uk.
January 8, 2008 at 10:29 pm
I made this using felt with fabric as the lining, and i added earflaps and bear ears on top
January 26, 2008 at 1:34 pm
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February 14, 2008 at 12:19 pm
This is a great tute! I’m so in love with this hat pattern, and I admit i’m usually not the hat-wearing type! Just a question, any tips on resizing the pattern? I think it’d be really cute for my 2 year-old son aswell!
February 15, 2008 at 10:15 pm
My dd will definitely want one of these. Thanks
February 22, 2008 at 10:00 pm
That is so cute. You did an awesome job! :]
February 28, 2008 at 12:58 am
I was looking for instructions on how to make a HAT; was disappointed to only see instructions on how to make a cap.
February 28, 2008 at 9:47 pm
Thanks for the awesome pattern and instructions! I just got around to making one, and it turned out really nice.
March 5, 2008 at 2:26 am
I think I printed it wrong and just want to check, as mine came out 4.5 inches, which I think makes it 21 inches finished size. What are the flat edges of the hat pieces supposed to measure?
March 19, 2008 at 1:04 am
I made one and couldn’t believe how easy it was and how cute it turned out! Thanks!!
April 5, 2008 at 7:04 am
sew nice
May 1, 2008 at 5:30 pm
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June 25, 2008 at 3:52 pm
I just made one of these and I absolutely love it! Thanks so much for the pattern and instructions! I made a couple of modifications to suit my needs and I posted it on my blog
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January 23, 2009 at 8:18 pm
Tks for your nice explanation , very nice of you to share pictures and step-by-step. Do you happen to have a sun hat pattern? I’m trying to make me something to cover the sun out of my face during summer since my face is full of bad sun marks. Hugs and congratulations again!
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February 18, 2009 at 2:16 am
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February 28, 2009 at 4:45 pm
where do i find out what the abreviations mean and which way I should lay my fabric to cut it? can you help?
March 4, 2009 at 10:24 pm
@Chris:
CF = center front
CB = center back
Lay out with the flat parts of the upper pieces either with or cross grain (perpendicular or parallel to the selvege). For the brim (peak) draw a line between the little hash marks in the middle. This will be your grain line for that piece.
Good luck!
March 6, 2009 at 10:31 pm
This is wonderful – thank you for posting such detailed instructions and photos. I’m also making hats and have been trying to wrap my head around a problem: making them adjustable and lined. Aside from ‘hiding’ the elastic (at the back) with grosgrain ribbon, do you (or anyone) have any suggestions? Cheers
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April 8, 2009 at 7:35 pm
Thank you for your pattern and great instructions, I just made your cap from leftover cotton fabric I had made a dress from and it came awesome!!! I even added a matching fabric covered button. Very cool.
Thanks again for sharing..you rock
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