Free Pattern: Make a Hat

Free Pattern Make a Hat

Are you a hat person?  Have you ever sewn yourself a hat?  It’s been a while since I did a free pattern on this blog, but here is a hat pattern I hope you’ll like.

This hat has an oval crown, with side seams on the crown’s side and brim.  It has a slightly deeper brim than a classic bucket hat.  It’s easy to machine wash and can be squashed into a handbag or suitcase.


Free Pattern Make a Hat yellow hat


Fabric: Suitable fabrics are quilting cotton, drill, lightweight denim or baby cord.  As always, choose a fabric that you love and will enjoy wearing.

I used brown linen for one hat and yellow spotty cotton drill for the other.  Both came from Spotlight a long time ago.  I was originally going to make a hat in baby cord (I was thinking of a Corduroy Day project).  However, while I was searching for fabric I came across these offcuts which I liked better, and ended up making two hats.

How much fabric?  If you’re buying some you’ll need 45cm of 110 wide fabric, and the same of firm interfacing.  A lining can be easily cut out of a fat quarter.  However, you probably have something suitable at home in that fabric stash or left from something else.

Choose a firm interfacing, preferably iron-on.  I used Shapewell (a firm woven sew-in) because I didn’t have anything else handy.

Pick something fun for the lining; it will make you smile each time you put your hat on.  Here are the insides of my hats:


Free Pattern Make a Hat inside view brown hat

The brown linen hat has roses, from the collection of 1960’s fabric.


Free Pattern Make a Hat inside view yellow hat

The spotty hat also has a lining cut from the collection of 1960’s fabric.


Free Pattern Make a Hat inside view blue hat

My old blue hat has gingham. I’m wearing this hat while gardening here.


Free Pattern Make a Hat inside view old old hat

My old old version of this hat has fabric from favourite skirt.


Sizes and fit: You’d be surprised how many people in this world have big heads and have trouble finding hats to fit (or not, if you’re one of them).  A survey once in my sewing class revealed one in four are above the “average” 56cm (22″) head size.  This pattern is in sizes 54cm, 56cm, 58cm, 60cm and 62cm head circumference; pick the size to match the measurement of your head.  The pattern measures slightly bigger than the head measurement to allow for the stitching and the thickness of the fabric.  If you discover you need to tweak the fit, the interior ribbon can be cut up to 1.2cm (1/2″) smaller or bigger than the instruction’s measurement, and stretched or eased onto the hat.

Patterns: Download the hat pattern – all sizes are together.  It’s on 4 pages, landscape.  Be sure to print at 100%.  Sticky tape the sheets together matching the crosses at the corners.

Free Pattern Make a Hat All Sizes nested

For a classic bucket hat with a circular, rather than oval, top, there’s an optional round top (all sizes, one page):

Free Pattern Make a Hat Optional round top



Free Pattern Make a Hat Instructions page 1

Some photos to supplement the instructions:


Free Pattern Make a Hat all the pieces

Step 1 Cut out all the bits.


Free Pattern Make a Hat crown sewn

Step 2 Make the crown, one in lining and one in main fabric.


Free Pattern Make a Hat tiny snips to sew the crown

Sew the Top onto the Side with the side uppermost. Make some tiny snips in the Side to help it match the curve while you sew.


Free Pattern Make a Hat joining the crowns together

Join the two crowns together at the top, catching it at the quarter points.


Free Pattern Make a Hat joining the brim pieces

Step 3 Sew the brims together around the edge.


Free Pattern Make a Hat brim topstitching

Run some topstitching around the brim…


Free Pattern Make a Hat ric rac detail

…or some braid or ric rac…


Free Pattern Make a Hat triangular stitching detail

…or some fancy stitching like my old old hat.  There are eight triangles around this brim.


Free Pattern Make a Hat brim and crown ready

Step 4 The crown and brim ready to be joined.


Free Pattern Make a Hat brim and crown seam

The crown and brim pinned together waiting to be sewn.


Free Pattern Make a Hat attaching the ribbon

Step 5 Adding the interior ribbon.


Enjoy this hat pattern.









  1. Linda on November 22, 2017 at 8:06 pm

    Gorgeous hat Liz! I particularly like the large brim. I shall definitely be downloading the pattern. It is perfect for having in your bag while out and about. Thank you

    • lizhaywood on November 23, 2017 at 10:12 am

      Thank you Linda. I hope you have fun sewing it.

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