How to Make a Baker Boy Hat From Scratch

Julia Rafael
by Julia Rafael
8 Materials
2 Hours

Today, I'm going to show you how to make a baker boy hat. Women's baker boy hats are so stylish so I thought I would try to make one myself.

This DIY baker boy hat sewing pattern and the sewing instructions are included, so you can get started right away!

Tools and materials:

  • Tracing paper
  • Hat fabric
  • Lining Fabric
  • Ruler
  • Pencil
  • Sewing pins
  • Thread
  • Sewing machine
What is a baker boy hat?

Examples of baker boy hats.

How to make the baker boy hat sewing pattern

1. Create the pattern 

Fold a sheet of A3 paper (11.7 x 16.5 inches) in half and then in half the other way. 

From the 4-layered corner, along the short side of the paper, measure, and mark 11½ and 12½ centimeters (4½ and 4.9 inches). 

Marking the baker boy hat sewing pattern

From that same corner, measure, and mark 11½ and 12½ centimeters (4½ and 4.9 inches) from the corner in a quarter-circle radius on the paper.

Cutting out the baker boy hat sewing pattern

Connect the marks on the two lines and cut out the quarter circle along the 12½-centimeter (4.9-inch) line.

DIY baker boy hat sewing pattern

Unfold the paper and you now have a complete circle.

Second baker boy hat sewing pattern

For your second pattern piece, draw a 9 x 12-centimeter (3½ x 5.7-inches) rectangle on a new piece of paper.


From the top corner along the right short side, mark 3 centimeters (1.2 inches) from the corner. Then mark 5 centimeters (2 inches) from the top corner along the left short side.

Drawing a baker boy hat sewing pattern

Cut out the rectangle from the paper. Draw a curved line from the bottom left corner to the 5-centimeter (2-inch) mark on the left edge. 

Measuring the baker boy hat sewing pattern

Measure the circumference of your head and divide by 4. In this tutorial I measured 56 centimeters (22 inches) for my head, so divided by 4, I got 14 centimeters (5½ inches).

Draw a 14-centimeter line (or whatever your final measurement is) from the 3-centimeter (1.2-inch) mark on the right edge of the rectangle to the top edge of the rectangle.

Try to follow the same angle as the line you made from the bottom corner to the left edge.

Cutting out the baker boy hat sewing pattern

Connect all 4 of those markings and cut out your second pattern piece. 

Baker boy hat brim sewing pattern

For the third pattern piece, use a cap as a template. Trace the brim of that cap onto a piece of paper. 

Easy baker boy hat sewing pattern

Roughly cut it out but then fold your cut paper in half and trim as necessary so that your brim pattern piece is symmetrical.

Baker boy hat sewing pattern

The last pattern piece is the easiest one.

Cut a paper rectangle measuring 5 centimeters (2 inches) wide and, for the length, the measurement that is the full circumference of your head (56 centimeters or 22 inches in this tutorial, or 28cm and 11 inches if you are cutting it on a fold) plus 1 centimeter (0.4 inches) for a seam allowance.

Cutting out the fabric pieces

2. Cut the fabric

Use your paper pattern pieces to cut the following:

  • 1 circle from the main fabric and one from the lining fabric;
Fabric pieces for the DIY baker boy hat
  • 2 rectangles from the main fabric;
  • 2 brims from the main fabric, adding some extra fabric at the bottom to make it easier to sew; and
DIY baker boy hat fabric pieces
  • 4 of the custom curved pieces, 2 from the main fabric and 2 from the lining fabric. 
How to sew a baker boy hat

3. Sew!

Sew the brim pieces together along the curved edge, with right sides facing and using a straight stitch. Then, cut notches in the seam allowance and turn the brim right-side out. 

Sewing a baker boy hat

Topstitch three lines, 1 centimeter (0.4 inches) apart, around the seam to make the brim stronger. Finally, topstitch the straight open edge of the brim.

Sewing the baker boy hat together

Now, sew the two main-fabric curved pieces together along the short edges and then do the same with the two lining-fabric curved pieces. That gives you two open circular shapes in total.

Pinning the fabric ready to sew

Pin the fabric curved piece to the fabric circular piece, all the way around the outer edge. Do the same with the lining curved and circular pieces.

Sewing the curved pieces

Sew the curved pieces to the circular pieces along the outer edge with a straight stitch.

DIY baker boy hat tutorial

Now you can see how it’s all coming together!

Folding and sewing the rectangles

Fold each of the long rectangles in half lengthwise, with right side facing, and sew the short open edge together. 

Pinning and sewing the hat

With right sides together, pin, and then sew one of the long pieces to the hat, at the open edge, using a straight stitch.

Pinning and sewing the hat brim

Pin and sew the hat brim to the hat with right sides facing.

Pinning the long strip

Now take the second long strip and pin and sew it to the hat just as you did before.

Adding lining to the baker boy hat

Take the lining-fabric circle and pin and sew it to the hat with right sides facing, wrapping the lining piece around the main fabric piece.

Leave one small section open to allow you to turn the hat right-side out.

Turning the hat right sides out

Turn the hat right sides out and tuck the lining into place. Then, use a straight stitch to sew up the gap you just left around the edge.

Topstitching around the hat for a nice finish

Finally, topstitch around the whole hat to give it a clean, finished look.

How to make a baker boy hat

How to make a baker boy hat

I hope you love wearing your new DIY baker boy hat. Leave me a comment to let me know how these instructions worked for you.

Suggested materials:
  • Tracing paper
  • Hat fabric
  • Lining Fabric
See all materials

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