How to Make a Bucket Hat?

How to Make a Bucket Hat?

Bucket hat is a fashion accessory that can match almost any outfit. They are also very helpful in protecting hair from sunlight. Instead of rushing to the store, how about making one yourself? Knowing what to do means you can sew a new bucket hat for every occasion!  (Note: If you want to get custom bucket hats in bulk, contact Yaohat bucket hat manufacturer here >>)

Part 1: Cutting the Pieces

1. Choose your fabric

You will require two colours, one for the outer layer of the hat and one for the inner layer. You can wear cotton on one side and canvas or denim on the other side to make it comfortable and stylish.

2. Cut two 8-inch (20.32-centimetre) circles

You need to cut out a circle from each fabric. This circle will be the top of the hat. You will need a seam allowance of ½ inch (1.27 cm). If your head is small, you can cut out a smaller circle. Similarly, if you have a bigger head, you need to cut out a bigger circle.

3. Cut the body pieces

You require two 12” x 3” (30.48 x 7.62 cm) rectangles of fabric. There should be a total of four rectangles of fabric.

If you want a bigger hat, please make a four-inch (10.16 cm) wide rectangle.

If you want to cut a large/small circle, cut out each rectangle to measure half of the circle.

4. Cut the brim pieces

You need a total of four pieces of the same fabric, two of each fabric. These fragments should be three inches wide. Their inner curve should be 30.48 cm (12 inches) long, and the circumference of their outer curve should be 18 inches (45.72 cm).

If you need wider margins, please trim the arches 4.5 inches (11.43 cm) wide.

If you want to cut large/small circles, please align the inner curve of the edge with the length of the adjusted rectangle.

5. Consider cutting some fusible interfacing

If your fabric is very thin, you can add some fillers or interfacing. Cut the interfacing ½ inch (1.27 cm) smaller than your previously cut pieces. Then iron them to the opposite side of the fabric. This should be done only to one part of the fabric, either inner fabric or outer fabric.

Part 2: Sewing a Bucket Hat

1.Pin and sew the rectangles together

Connect the two outer rectangles so that their front faces touch. Sew the two narrow ends with ½ inch (1.27 cm) of the seam allowance.

Repeat this same step for the inner fabrics.

2 Pin and sew the brim pieces

Pin the outer brim pieces with the right-side facing inward. Sew only at the narrow and straight ends. Use a seam allowance of ½ inch (1.27 cm).

Repeat this procedure for the two inner fabric pieces.

3.Press the seams open on the body and brim pieces

Put part of the hat body on the ironing board with the seam facing you. Use an iron to separate the seams. Flatten the seams by pressing. Repeat this step for all seams on the body and brim pieces.

4.Pin and sew body pieces to circles

Fix the top edge of the outer body piece to the outer edge of the matching circle. Ensure that the wrong side is facing out. Use ½ inch (1.27 cm) of seam allowance to sew the edges.

Repeat this procedure for the two inner fabric pieces.

5.Pin and sew the brim to the body

Pin the inner edge of the matching hem to the bottom edge of the body. Make sure that the wrong sides are towards you. Sew it with a seam edge of ½ inch (1.27 cm).

Repeat this step for the inner fabric pieces.

Part 3: Assembling the Bucket Hat

1.Tuck one hat into the other

Turn out the right side of the hat; leave the other one as it is. Insert the first hat into the second hat so that the front sides are pressed against each other, exposing the wrong sides.

2.Pin and sew around the brim’s outer edge

 Sew with ½ inch (1.27 cm) of the seam allowance. Leave four inches (10.16 cm) ample space for turning. Remove the pins during sewing.

3.Cut notches on the seams to reduce brim

Make a notch every ¾ inch (1.91 cm) at the seam on the top of the hat. Make an incision at every inch (2.54 cm) to the seam along the outer edge of the brim. The notch should be slightly less than half an inch to avoid cutting during stitching.

There is no need to cut notches into the seams between the body and brim pieces.

4.Turn the hat inside out through the gap.

Shape the hat to fit one piece into another; if necessary, use skewers or knitting needles to push out the seams along the edges.

Part 4: Finishing the Bucket Hat

1.Tuck and press the gap shut

Fold the edge of the gap ½ inch (1.27 cm) inward to align it with the rest of the edge. When finished, use an iron to flatten the edges.

2.Topstitch around the brim’s outer edge

Try to sew ¼ to ½ inch (0.64 to 1.27 centimeters) away from the outer edge of the brim.

3.Add more rows of topstitching

The step is not compulsory, but it will make your hat look more professional. Just sew another 4 to 5 lines along the brim. Leave up to ¼ to ½ inch (0.64 to 1.27 cm) of space between each row.

4.Topstitch the top and body of the bucket hat.

Once again, if you don’t have to add a nice touch to your hair, this step is not necessary. But if desired, sew a backstitch ¼ inch from the seam on the top of your hat body. Then sew it at the bottom. The edge of the body part is also ¼ inch (0.64 cm) from the seam.

Leave a Reply