You will now insert the plastic brim stiffening. Slightly smaller is better than slightly bigger, here, so sew to the inside of the line if you find yourself choosing. Sew the two brim pieces, right sides together, along the outer edge - you have a drawn line here to help show you exactly where to stitch. Now it's time for the brim, which is a bit tricky.
HEX FIEND LINE DELIMITYER HOW TO
Look at the next step for how this is done and you'll see how to cut it. This needs to be a bit taller than the finished pocket as you'll be folding a bit over at the pocket edge. (Don't worry about trying to match the exact size of the crown piece edges multiplied by 6, or anything you'll work this out when attaching the crown to the band as long as you've got the right general crown size.) Optionally, cut a pocket piece. If your head is larger or smaller, adjust this accordingly, and leave about a half inch or so for hair and comfort. This assumes your head is average size, which is about 22-23 inches. Cut it by drawing and cutting a rectangle 1-1/2 inch wide and 23-1/2 inch long. I didn't add a pattern for the band because it is just a rectangle. If your eye isn't that accurate (and I've been doing this for 25 years), do the tracing and then draw a second line 1/4 inch outside it and cut along that one. I usually do this by tracing the plastic brim piece and then cutting 1/4 inch out from that. You will need to add 1/4 inch of seam allowance to these. Cut two of the brim pieces out of fabric. Note that the brim piece does NOT include seam allowance, for this purpose. The easiest way to do this is to trace the pattern with a sharpie and cut along those lines. Cut a brim out of your scrounged plastic material. The crown pieces have seam allowance, 1/4 inch, marked on them. Cut another six out of your lining fabric, if you choose to line your hat. No special stitches are required, any old sewing machine will do.Ĭut six each of the crown pieces, the ones shaped like a bulgy triangle. Finally finally, you need thread and a sewing machine. You can substitute another piece of fabric the same dimensions as the band, but I find quilt binding is easier and faster. It's available in packages of 3 yards in any fabric store. Finally, you need about 4 or 5 feet of quilt binding, which is like very wide seam binding, an inch wide.
I mentioned the plastic for the brim in the intro. If you have enough, and it's not super heavy, you can probably use your main fabric. I suggest using a lining so you don't get bits of thread in your hair whenever you wear your hat. One shirt would be plenty, I used two only because I wanted a contrast. You need about 2 or 3 square feet for either hat, which is usually not more than 3/8 of a yard. If your fabric is very stretchy, interface the band so it's more stable. Most materials are suitable, except for very thin ones. The orange one used to be two shirts, and the brown one used to be two handbags. I like to make these hats from reclaimed materials. However, the technique is almost exactly the same for both, just the pieces are slightly different sizes. This tutorial shows the construction of the brown hat as I'd already made the orange one. I also like to put pockets on the crown, as I did with the brown one. The zipper was part of the neckline of the original shirt, which I cut to fit. The orange one has a zipper on the crown under which you can put any kind of Sekrit Surprize. The smaller brim would probably fit on a plastic milk or juice jug. Other possible sources are plastic spiral notebook covers (not the cardboard ones, though) or blister packaging if the product is big enough to have about 6" x 4" of flat (or gently curved) plastic. The brims are made of plastic rescued from the packaging for a dress shirt. Once you've made a couple, you can throw one together in about 45 minutes. I like to make these from reclaimed materials. Here's a pattern and instructions for two styles of brimmed hats with crowns made from six identical pieces.
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