Your resident "grilling aficionados" will love this chef's hat made especially with them in mind. Circling the grill, hot dogs and hamburgers let everyone know exactly what's on the menu!

Click here for apron instructions

Instructions:

To make the hatband, mark a 25" by 5" rectangle on your fabric and center the Grill Master design in the rectangle. Using medium-weight, cut-away stabilizer, sew out the Grill Master design. Use one large piece of stabilizer, and it will double as the interfacing to stiffen the hat band. Next, place the Hot Dog and Hamburger border next to the Grill Master lettering and extend the border to the ends of the rectangle on both sides.  When you are finished embroidering, add a seam allowance to the outside edges of the rectangle and cut out the embroidered rectangle. Cut out a second rectangle of the same size from the remaining fabric; set aside.

Now mark and cut out a 24" circle from your fabric. This will be the top part of the hat.

Make a 4 1/2" cut into the edge of the circle. This will be the back opening of the hat.

Place the two rectangles right sides together and stitch the seam for the bottom of the hat band. Turn right side out and press.

Starting on one side of the slit in the circle, make 2 lines of basting stitches along the entire edge of the circle to the other side of the slit. Gather the circle to fit the length of the hat band.

Fit the circle to the hat band and, with right sides together, stitch the embroidered part of the band to the top of the hat.

With the hat inside out, bring the unembroidered inner band up to cover up the seam allowances.  Pin in place and then top stitch to secure.

Cover the edges of the back opening by stitching the double-fold bias tape around the unfinished edges.

This photo shows the bias tape in place.

To make the closure adjustable, determine where you want the hook and loop closures to be, and sew onto the hat band. Make sure that they face each other to fasten properly.