Learn to Sew a 6 Panel Bucket Hat and Skull Cap

8 materials
$15
3 Hours
Easy

Hats are the best accessory, especially when it’s a bad hair day! Download this free pattern here and learn how to sew a 6 panel bucket hat or skull cap to add to your hat collection.

Tools and materials:

  • Fabric
  • Interfacing
  • Bias binding
  • Velcro
  • Scissors
  • Pins
  • Marker
  • Sewing machine
sew a bucket hat, Bucket hat
Bucket hat

Cut the fabric 

To start off, I used the pattern that doesn’t have an added seam allowance, to cut out the fusible fleece. I then ironed it onto the fabric. 

sew a bucket hat, Cut around the interfacing
Cut around the interfacing


I then cut around the interfacing, leaving a 1cm (0.4 inches) seam allowance. I then used those pieces as a template to cut out the inner pieces of the hat. 

sew a bucket hat, Sew sets
Sew sets

Sew the pieces together 

Next, I took two pieces and sewed them together to create a set. I sewed along the interfacing line all the way from the top to the bottom. 

sew a bucket hat, Finger press the seams
Finger press the seams


I finger pressed down the seam allowance and then sewed the third piece onto the set. 

sew a bucket hat, Women s bucket hat
Women’s bucket hat


I had two 3 piece sets and then trimmed off the bulky fabric. 

sew a bucket hat, Pin the point
Pin the point

Sew the outer crown together 

I then used a pin to mark where the point of the hat is in the middle of the triangle. 

sew a bucket hat, Match the two pieces
Match the two pieces


I matched the two pieces together and then sewed from the middle so that I could just stop and check that everything was lined up properly. 

sew a bucket hat, Sew the brim pieces
Sew the brim pieces

Sew the brim 

For the brim, I sewed the pieces together and then finger pressed open the seam allowance. 

sew a bucket hat, Easy bucket hat
Easy bucket hat


Next, I pinned and sewed the brim pieces right sides together. 

sew a bucket hat, Snip around the brim
Snip around the brim


I grabbed a pair of scissors and snipped around the brim and then ironed it. 

sew a bucket hat, Sew a women s bucket hat
Sew a women’s bucket hat


Next, I sewed along the seam of the brim to ensure that the seam allowances point towards the inner fabric. 

sew a bucket hat, How to make a bucket hat
How to make a bucket hat

Sew brim lines 

I then sewed along the brim to create the hat brim lines. 

sew a bucket hat, Mark the center
Mark the center

Mark the center 

Once I had sewed all the brim lines, I marked its center. 

sew a bucket hat, Mark the center of the crown
Mark the center of the crown


I also marked the center of the crown. 

sew a bucket hat, Match up the markings
Match up the markings


I then went ahead and matched up the markings on the crown and the brim of the hat. 

sew a bucket hat, Sew them together
Sew them together

Sew the pieces together

Once I had pinned the pieces, I sewed them together. 

sew a bucket hat, DIY bucket hat
DIY bucket hat

Add the inner crown 

I then added the inner crown piece and sewed it in place. 

sew a bucket hat, Add binding
Add binding

Add binding 

Next, I sewed some binding along the edge of the inner crown. This adds an extra layer and helps keep the hat on your head and also covers up the raw edges. 

sew a bucket hat, Hand stitch the inner and outer crown
Hand stitch the inner and outer crown

Hand stitch the inner and outer crowns 

I then hand stitched the inner and outer crown together at the top of the hat. 

sew a bucket hat, Make a bucket hat
Make a bucket hat

Make a shorter brim 

If you want to create a hat with a smaller brim, you can do it easily by simply taking off about an inch or two from the pattern. 

sew a bucket hat, Cut an arc
Cut an arc

Make a skull cap 

To make a skull cap, I simply cut an arc shape into the crown of the hat. 

Add bias binding 


I then added bias binding to the arc. 

sew a bucket hat, Fold over one end
Fold over one end


To get started on the brim, I folded over one end of the rectangle. I then sewed on the brim right side facing down. I then understitched so that the seam allowance stayed on the right side. 

sew a bucket hat, Fold the brim
Fold the brim


I folded the brim about an inch towards the inside of the hat and also folded the raw edge of the brim inward. 

sew a bucket hat, Pin the folds
Pin the folds


I pinned the folds in place and sewed around the outside of the brim. 

sew a bucket hat, Add velcro
Add velcro


I used some extra denim I had and sewed a small piece of rough velcro onto it. I placed the end of the denim piece inside the layers of the brim and sewed it in place. I then did the same with the other side of the velcro and sewed it so that the two velcro pieces would be facing each other. 

sew a bucket hat, How to sew a bucket hat
How to sew a bucket hat


I love that it’s so easy to make three different hats from one pattern. Which of these hats would you make? Let me know in the comments below! 

Suggested materials:

  • Fabric
  • Interfacing
  • Bias binding
See all materials

Comments

Join the conversation

 1 comment
Your comment...
Next