Embroidery Library

Boo-tiful Witch Hat

Free project instructions to create a boo-tiful witch hat.

Free project instructions to create a boo-tiful witch hat.


Celebrate Halloween in style with an embroidered witch's hat. Perfect for trick-or-treating with the kids, handing out candy on October 31, or Halloween party attire!

 

Project Needs & Notes:


- 1 3/4 yards (total) polyester or wool felt (two colors: 1 yard of black and 3/4 yard of orange)
- 3/4 yard stiff double-sided fusible interfacing (at least 24" wide)
- Medium-weight cutaway stabilizer
- Air-erase pen or dressmaker's pencil
- Hot glue and gun
- Pinking shears
- Compass rule
- Measuring tape
- Masking tape
- Ribbon (optional for hat bands: used 1 1/2" wide and 1/2" wide ribbon)
- Decorative items like faux flowers, birds, and spiders

The designs used in this tutorial is M8249, Happy Halloween with Bat.

Finished Size:
15 1/2" high (from the bottom to the point of the cone) x 20" wide (at the brim)

This project was featured in the following:
Spooktacular Halloween Lookbook



To get started, use the chart below to find the size. The hat used in this tutorial is a size 7 hat. Measure the head above the eyebrows and ears at the widest part (to the nearest 1/8") with a tape measure.

 
XS S M L XL XL
Size 6 1/2 6 5/8 6 3/4 6 7/8 7    7 1/8 7 1/4 7 3/8 7 1/2 7 5/8 7 3/4 7 7/8
Inches 20 1/2 20 3/4 21 1/8 21 1/2 21 7/8 22 1/4 22 5/8 23 23 1/2 23 7/8 24 1/4 24 5/8
Metric 52 53 54 55 56 57 58 59 60 61 62 63

Free project instructions to create a boo-tiful witch hat.

Lay the felt flat with the right side facing up. Tape the edges down with masking tape to hold the fabric in place.

Use this formula to adjust for different sizes:

- Divide your hat size by 7 (if the hat size is 7, then 7 divided by 7 is 1).

- Then, take that number and multiply it by 15.25 (1 multiplied by 15.25 is 15.25).

- Add 1" to that number to account for the thickness of the lining (15.25 plus 1 is 16.25").

That number is the distance between the end point of the compass and the marking end of the compass. Set your compass rule using the number you just calculated (here that number is 16.25"). Place the end point of the compass right on the corner of the fabric and draw a line across the fabric as shown. Cut the fabric along the line.

Free project instructions to create a boo-tiful witch hat.
A template, or printout of a design, is an excellent tool to help with placement.

Print a template of the design from your embroidery software.
If you do not have embroidery software, Wilcom's TrueSizer is
a free program to use.

Center
the template within the fabric as shown. Allow about 3" of space in between the bottom edge of the design and the bottom edge of the fabric.

Mark the center point and vertical and horizontal axis lines.

Free project instructions to create a boo-tiful witch hat.

Hoop the fabric and stabilizer together, aligning the marks on the hoop with the marks on the fabric.

Free project instructions to create a boo-tiful witch hat.

Free project instructions to create a boo-tiful witch hat.
When the design has finished, trim away the excess stabilizer from the backside of the embroidery.

Free project instructions to create a boo-tiful witch hat.
To prepare the inner lining, lay the embroidered front piece on top of the felt, pin in place, and cut around the shape of the embroidered piece.

Free project instructions to create a boo-tiful witch hat.
To create the cone, lay the embroidered piece flat with the embroidered side facing down.

Add a line of hot glue along one of the straight side edges.

Bring the straight edges together, overlap them by about 1/2", and press in place. Repeat this for the inner lining fabric as well.

Free project instructions to create a boo-tiful witch hat.
Cut two pieces of felt and one piece of stiff double-sided fusible interfacing to 24" x 24".

Layer them together as follows:

Lay the underside felt fabric down first with the wrong side facing up.

Place the interfacing on top of the felt and then place the top side felt fabric on top of the interfacing with the right side facing up.

Then, using an iron and pressing cloth, press both sides of the felt to activate the adhesive on the interfacing (follow the instructions on the interfacing for more information).

Free project instructions to create a boo-tiful witch hat.
Set the compass rule to 10" -- place the end point of the compass in the center of the fabric and draw a circle. This is the outer edge of the brim.

Free project instructions to create a boo-tiful witch hat.
Next, lay the fabric flat with the top side of the brim fabric facing up.

Again, tape the fabric place along the sides to hold it in place.

Set your compass to the size of the hat plus 1" (to account for the inner lining).

The hat in this tutorial is a size 7, so 7 plus 1 is 8". Therefore, the compass is set to 4" to create an 8" diameter circle.

Place the end point in the center of the fabric and draw a circle.

Free project instructions to create a boo-tiful witch hat.
Then, take the last measurement and subtract 2" (8" minus 2" is 6").

Set your compass to this adjusted size (here it is set at 3" for a 6" diameter).

Place the end point of the compass in the center and draw another circle. This is the allowance for adding the cone to the hat.

Free project instructions to create a boo-tiful witch hat.
Cut out the center circle only (cut through all three layers).

Free project instructions to create a boo-tiful witch hat.
Cut slits in the fabric about every inch, cutting from the hole in the center up to the next line.

Then, using a pinking shears, cut around the outside circle.

Free project instructions to create a boo-tiful witch hat.

Flip the brim over with the wrong side facing up.

Align the bottom edge of the embroidered cone with the inner circle on the top side of the brim.

Fold the tabs of the brim back, add a drop of hot glue, and press the tabs in place along the entire inside of the cone (the bottom edge of the cone should be flush with the top side of the brim).


Free project instructions to create a boo-tiful witch hat.

Insert the inner lining inside the cone.


Free project instructions to create a boo-tiful witch hat.

Add hot glue on top of the tabs along the underside of the brim.

Press bottom edge of the inner lining in place.


Free project instructions to create a boo-tiful witch hat.

You can add embellishments like ribbon, faux flowers, birds, and spiders for a personal look.

Here ribbon was hot glued around the base of the cone to create a hat band.


Free project instructions to create a boo-tiful witch hat.

This witch's hat is the perfect way to add a spooktacular look to any outfit on October 31.

Choose colors, embroidery designs, and decorative accents to suit your style.


Boo-tiful Witch Hat



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Pin it yourself using the "Pin It" button on this page.



Questions or comments? Let us know! Send an email to us; the address is stitch@emblibrary.com.

Products used in this Project:

Happy Halloween with Bat $3.99 - $4.99

Available in 2 Sizes:

4.86" x 5.29" | 3.56" x 3.86"

Trick or Treat with Skull $3.99 - $4.99

Available in 2 Sizes:

4.86" x 4.98" | 3.76" x 3.86"