This summer’s hot topic: bucket hats! If you’re looking for a summer accessory that’s both stylish and provides shade from harsh summer rays, we’ve got you covered. You can easily sew your own thanks to our free bucket hat pattern. To make it reversible, use 2 fat quarters of coordinating fabric designs or 2 designs on a split Fill-a-Yard! Both sides of our hat are a different animal print so we can switch between a leopard and cow print bucket hat depending on our moooooo-d that day.
Follow along to learn how you can make a bucket hat with our Lightweight Cotton Twill for a cool summer look. Our free hat sewing pattern could also be used to create a fuzzy and durable winter bucket hat with our Dogwood Denim™ on one side and Minky on the other to add a layer of insulation.
If you want to make the hat smaller or larger, you can alter the pattern by adding or subtracting 1/2″ (1 cm) around each of the pieces, repeating if needed to reach the desired size. This is a great method for kid’s bucket hats!
Iron your fabric smooth and pin the bucket hat pattern on top of one of your fat quarters. Make sure when positioning the crown and brim pieces that the “fold line” edges of the pattern are placed along a folded edge of your fabric. When the fabric is cut, you should be able to open the fold and have a correct sized crown and brim that’s double the length of your original pattern piece.
Cut one top, two brims, and two crowns, giving you a total of five pieces to work with. Later on, we’ll cut another set of the same pieces from the other fat quarter for the reversible side.
Brim: The projecting edge at the bottom
Crown: The sides, right above the brim
Top: The part that touches the very top of your head
Pin your crown pieces at the short ends, with right sides (the sides of the fabric with the design showing) facing each other, and stitch together with a 1/2″ (1 cm) seam allowance. You should have a big ring!
Iron your seams flat, then add two topstitches (a stitch designed to be seen on the outside) on both sides of each seam. Not only is this stitch decorative, but it also reinforces your sewing. You can use thread that matches your fabric’s colors, or go with a contrasting color like we did!
Now you can attach the top piece to the crown piece with right sides facing each other. This process can be a bit tricky as we’re working with a round seam, but just pull the fabric tight as you go and use as many pins as you need.
Pin the four notches first, then pin between these marks and distribute the rest of your pins around the circle until even. Sew these pieces together with a 1/2″ (1 cm) seam allowance, and iron your seam flat.
For a cleaner look, consider using the notching method before ironing your seam flat. Take some scissors and cut little slits about 1/4″ (1/2 cm) into the edge of the seam, making sure to not cut through the stitch itself. This is great for curved seams like the one we just made by releasing the tension and allowing for easier pressing.
Next, sew a line on top of the hat about 1/4″ (1/2 cm) down from the edge of the top part’s seam. Just like in step 3, this helps both reinforce and decorate your seam.
Similar to how we put together the crown, pin your brim parts with right sides facing at the short ends and stitch them together with a 1/2″ (1 cm) seam allowance. Iron the seam apart and reinforce/decorate with a topstitch on the outside.
Place the brim on the crown, right sides together. Similar to step 4, pin around the edges making sure the fabric is evenly secured, and sew in place. Once again, iron your seam flat and topstitch on the outside. Now you have one side of your bucket hat!
However, we need two sides. Repeat steps 1-7 with your other fat quarter so you end up with two hats.
Once you have your two hats, pin them together by the raw brim edges, this time with the wrong sides (non-design side) facing instead of the right sides.
Now stitch the brims together 1/2″ (1 cm) from the raw edge. If you’d like to add more structure to your hat, consider sewing rings around the edges of the brim about 1/2″ (1 cm) apart. You can also border your edge with bias tape, but we decided to go with the fun frayed edge that Lightweight Cotton Twill offers.
And you’re done! Enjoy your new bucket hat!