Tools and materials:
- Bias binding
- Sewing machine
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.
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.
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.
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.
I finger pressed down the seam allowance and then sewed the third piece onto the set.
I had two 3 piece sets and then trimmed off the bulky fabric.
I then used a pin to mark where the point of the hat is in the middle of the triangle.
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.
For the brim, I sewed the pieces together and then finger pressed open the seam allowance.
Next, I pinned and sewed the brim pieces right sides together.
I grabbed a pair of scissors and snipped around the brim and then ironed it.
Next, I sewed along the seam of the brim to ensure that the seam allowances point towards the inner fabric.
I then sewed along the brim to create the hat brim lines.
Once I had sewed all the brim lines, I marked its center.
I also marked the center of the crown.
I then went ahead and matched up the markings on the crown and the brim of the hat.
Once I had pinned the pieces, I sewed them together.
I then added the inner crown piece and sewed it in place.
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.
I then hand stitched the inner and outer crown together at the top of the hat.
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.
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.
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.
I folded the brim about an inch towards the inside of the hat and also folded the raw edge of the brim inward.
I pinned the folds in place and sewed around the outside of the brim.
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.
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!
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