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Determining Hat Size:
Measure the circumference around the head above the eyebrows and ears. Find
the hat size below and refer to it while following the project
instructions.
The large size will work for 23 1/2
inches, the medium size will work for 22 1/2 inches, and the small
size will work for 21 1/2 inches.
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Click here to download the hat pattern.
The pattern is split in five pieces and will print on five pieces
of paper. |
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The brim section of
the pattern has four sections. Cut around the straight edges of the pattern and tape them
together.
Set the patterns aside for now. |
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Create full-size paper templates of the
designs. Cut the designs down to size to make them manageable.
Measure and mark the side piece on the light twill fabric, based on
the size of the hat:
Large =
26 3/4 x 5 1/2
inches
Medium = 25 3/4 x 5 1/2 inches
Small = 24 1/2 x 5 1/2 inches |
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Find the
center of the rectangle by measuring the ends and dividing by
two. Make marks on the ends, and then draw a line across the
fabric connecting the marks. This line will be used for placing
the designs.
Mark the center by measuring the line
and dividing by two. Poke a hole in the center of the first
design and align it with the center mark. Place the other two
designs on the line about 3 1/2 inches from the center design (from edge
to edge). Mark the vertical axis points of all the designs onto
the fabric. |
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Remove the templates and draw lines connecting the vertical axis
marks. These lines will be used for hooping. |
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Lightly spray the fabric with temporary adhesive. Hoop the fabric
and stabilizer together for the first design, aligning the lines
on the hoop with the lines on the fabric. Align the needle
directly over the center point on the fabric, and embroider the
first design.
Repeat hooping and embroidering the two other designs. |
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Once the designs are
embroidered, carefully cut away the excess stabilizer. |
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Cut out the
shape of the side piece. |
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Cut two pieces of the brim fabric. Place the brim pattern on one
piece of the denim fabric, pin in place, and cut the pattern,
including the notches, and then... |
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...cut out the hole in the center.
Cut along the outer line for the large size, cut along the middle
line for the medium size, and cut along the inner line for the
smallest size.
Cut 1/4 inch long slits along the inner edge at about every inch.
Remove the pins and use the same pattern to cut out the other piece
of denim fabric. |
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Remove the pins from
the second piece of denim fabric.
Trim the pattern to use for the interfacing. Cut 1/8 inch in from
the outer edge and 5/8 inch in from the inner circle. |
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Lay the pattern on
the interfacing, pin in place, and cut out the pattern. |
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Lay the two pieces
of denim, right sides together, and pin in place. |
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Sew a 1/2 inch seam
around the outer edge only. |
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Turn the fabric right side out and press the seams. |
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Add the interfacing between the two layers of denim fabric. |
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Press the brim on both sides to activate the fusible interfacing. |
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Sew a 1/8 inch seam
along the outer edge of the brim. Sew four more seams every 1/4 inch
towards the center creating concentric circle seams. |
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Pin the top section
pattern to the light-colored fabric and cut out the shape, including the notches. Take out the pins and
reuse the pattern to cut out another piece of the same fabric with
the same pattern. |
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Lay the pieces wrong
side together and sew a 1/2 inch seam along the outside edge of the
fabric. |
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Cut a piece of terry cloth the same size as the size of your embroidered
side fabric.
Large =
26
3/4 x 5 1/2 inches
Medium = 25 3/4 x 5 1/2 inches
Small = 24 1/2 x 5 1/2 inches
Fold over the long sides 1/4 inch and press in place. |
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Fold the long sides
of the embroidered fabric together over to the wrong side 1/2 inch
and press in place. |
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Sew a 1/4 inch seam along the long sides of the fabric and then
the terry cloth lining. |
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Lay the embroidered
side fabric with the terry cloth liner wrong sides together.
Insert 1/2 inch of the top sections allowance between the
embroidered fabric and the terry cloth liner. Pin in place.
Be sure to align the top section with a narrow side of the oval
facing the side pieces. |
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Sew a 1/4 inch seam along the top edge of the side piece,
inserting the allowance of the top section in between the side
sections as you sew.
Sew the side, top, and lining together, sewing
out from the center and stopping about 2 inches from the end of the
side pieces. Then sew from the center out on the opposite
side, also stopping 2 inches from the end of that side. |
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Align the bottom ends of the sides together, right sides facing
each other. Pin in place. |
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Sew a seam starting 1/2 inch in from the bottom edge and angle the
seam up to meet at the top. |
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Trim off the excess fabric leaving about a 1/2 inch allowance. |
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Align the top
portion with the opening in the center of the brim. Insert the allowance of the brim in between the layers of the
side section and pin in the front and back only.
Then sew a seam
right along the edge of the side section all the way around,
inserting the allowance of the brim as you sew. |
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