How to Make a DIY Bucket Hat Without a Sewing Machine

Mset Fashion Design
by Mset Fashion Design
11 Materials
$5
3 Hours
Easy

A bucket hat is a perfect accessory for those days when you need some sun protection or your hair isn’t at its best. This DIY bucket hat is a chic head topper that even a novice at sewing can whip up in a single afternoon.


My bucket hat pattern uses just 3 pieces to make this charming chapeau. Let me show you how to make the DIY bucket hat right now.

Tools and materials:

  • Outer fabric
  • Satin lining or second outer fabric if you want to make it reversible
  • Fusible interfacing
  • Measuring tape
  • Pen
  • Ribbon (optional)
  • Pins
  • Iron
  • Needle and thread
  • Sewing machine (optional)
  • Decorative pearls, studs, or applique (optional)
Sketch of the DIY bucket hat

1. Get your measurements

You can use new or repurposed fabric. There are 3 parts to the hat: circle, headband, and brim. The measurements for these pieces will be the same for the outer fabric, fusible interfacing, and lining so keep your measurements to measure all 3.

Measuring the head circumference

First, you’ll need to measure your head circumference. Don’t make it too tight. Calculate your head circumference and subtract 4 inches. Divide your result by 6.28 to find the radius. 

Making the circle

2. Make the circle

To draw the circle you could either use your measuring tape or use a ribbon tied to a pen. Mark your radius measurement on the ribbon and cut the ribbon at the mark. Hold the ribbon edge down with your non-dominant hand and pull to the use the pen to mark across the fabric.

Folding the fabric

Fold a piece of fabric in half.

Drawing a half circle

Draw a half circle with the radius along the fold.

Cutting out a circle

Cut this circle out with a ½-inch seam allowance.

Making the headband

3. Make the headband

Use a piece of fabric that has a right-angle corner.

Folding the fabric diagonally

Fold the fabric in half diagonally, right sides together. Mark a ½-inch seam allowance from the raw edge. Use the top point of your triangle as the center.

How to make a bucket hat from scratch

Calculate 4 times your radius and draw the first arc with your result. Add 3 ½ inches to this measurement and draw the second arc. Write down the second measurement to use for the top of the brim.

How to make a bucket hat

Double check your measurements with your measuring tape if using the ribbon method to make sure your results are accurate. Cut out the headband with a ½-inch seam allowance.

How to make a bucket hat without a sewing machine

Discard the top part as you’re only going to use the wider bottom part.

Making the brim of the hat

4. Make the brim

Use a piece of fabric that has a right-angle corner. Fold the fabric in half diagonally, right sides together. Mark a ½-inch seam allowance from the raw edge. Use the top point of your triangle as the center.

DIY bucket hat tutorial

Draw the first arc using your bottom headband measurement. Add 2 ½ inches to the radius for the brim length. Draw the second arc. Cut out the fabric with a ½-inch seam allowance. 

Pattern pieces

You should have these 3 pieces.

Making the fusible interfacing pieces

5. Make the fusible interfacing pieces

Cut the fusible interfacing to match the circle, headband, and brim pieces.

Fusing the interfacing with an iron

Press the fusible interfacing to their corresponding pieces. Make sure the right side faces outward.

Folding the headband

6. Sew the headband

Fold the headband in half right sides together. Pin on the short side.

Sewing the headband

Sew together.

Pressing the seam open

Press the seam open to flatten.

Attaching the circle to the headband

7. Attach the circle to the headband

Place the circle around the inside of the headband right sides together.

Pinning the pieces together

Pin in place. Sew along the pinned edge.

Sewing the brim

8. Sew the brim

Fold the brim in half, right sides together. Pin on the short side. Sew together.

Pressing the seam open

Press the seam open to flatten.

Attaching the brim to the bucket

9. Attach the brim to the bucket

Keep the hat with the right sides inside. Place the brim inside so their right sides are together. Match up the seams. Pin there first.

Pinning the bucket to the brim

Pin all around. Sew along the pinned areas.

Cutting notches along the seam allowance of the brim

Cut notches all along the seam allowance of the brim.

Cutting notches along the seam allowance of the circle

Cut notches all along the seam allowance of the circle. 

Pressing the seam allowance open

Press the circle seam allowance open and the brim’s seam allowance up towards the headband.

Using a pillow for pressing

It’s helpful using a pillow for pressing the seam allowances. 

Sewing the bucket hat

10. Sew the bucket hat

Turn the hat right side facing out. Topstitch either by hand or machine across the circle at both the top and bottom of the circle seam. Topstitch just above the brim and along the center back seam.

Adding decorative details to the hat

You can add decorative details as I did.

Making lining for the bucket hat

11. Make the lining

Cut the fabric pieces to match. If you want to make this a reversible hat, use another fabric. If you want a lining, use satin for the circle and the headband with the same outer fabric for the brim. Repeat the steps for sewing.

Leaving a space unsewn

Leave a 1 ½ inch space unsewn between the headband and brim.

Attaching the lining

12. Attach the lining

Turn the hat so the right side faces inward. Place the lining inside so their right sides are together. Match up the seams.

Pinning the lining

Pin along the headband and the brim. Sew across at the brim.

Turning the hat to the right side

Cut the seam allowance in half after sewing. Use the opening to turn the hat right side out.

Tucking the lining inside

Tuck the lining inside. Press the brim.

Topstitching the brim edge and seam

Topstitch above the brim seam. Topstitch at the brim edge.

Sewing the opening closed

Sew the opening closed.

Sewing the lining seam allowance

Sew the lining seam allowance down.

DIY bucket hat

DIY bucket hat without a sewing machine

You’re done making this beautiful DIY bucket hat. Please let me know in the comments if you made this chic topper and where you wore it!

Suggested materials:
  • Outer fabric
  • Satin lining or second outer fabric if you want to make it reversible
  • Fusible interfacing
See all materials

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