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By Danika Herrick on March 8, 2024
By Courtney Napier on February 12, 2024
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! By selecting different designs for each side, you easily switch sides for different moods!
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!
While we’re using Lightweight Cotton Twill for our hat, you can use sturdy Dogwood Denim™, smooth Petal Signature Cotton™ backed with a medium to heavy-weight interfacing, or even soft and fuzzy Minky. Note: A fat quarter of Spoonflower’s Lightweight Cotton Twill is a bit wider than the traditional fat quarter, measuring 29″ wide rather than 21″. Take this into consideration when deciding how much fabric you need, as only two regular-width fat quarters may not be enough for this project. All of our fabric types can be found here with measurements and other details.
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.
While including a 1/2″ seam allowance around each 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!
49 comments
10 comments
Anna is a self-taught sewist, award-winning cosplayer and digital artist. In her free time, she’s either stitching up new costumes and creating fun content, binging some sort of animated series or snuggling her cats, Mina and Opal.
More About Anna Fletcher
Are there printable instructions for this? I can’t wait to try it! Thank you!
Hi Barbie!
And yes, there are! The pattern is linked in the materials section. Here’s the direct link: https://blog.spoonflower.com/wp-content/uploads/2021/07/SF-Pattern-SummerHat-EN-2.pdf.
Best,
Betsy
Spoonflower
I love the vibrant patterns showcased in these bucket hats! They add such a fun and stylish touch to any outfit.
I want to enlarge the size of the cap. How do I do that?
Hi there,
To increase the size of the hat, you’ll just need to extend the pattern’s edges a bit. You can transfer your cut pattern to another sheet of paper and cut a new one out with an extension of something like 1 cm all around, or just mark this on the original pattern papers before cutting. Test the new pattern and add/subtract more from the edges if needed!
Crafty regards,
Anna
Spoonflower
Do we have to add the seam allowance onto the pattern piece or is it included..
Hi Gayna,
Additional seam allowance is not required for this pattern and is already included in the measurements. However, based on my experience sewing this together I would recommend adding extra seam allowance if you’re making this for someone who has a larger head than average.
Crafty regards,
Anna
Spoonflower
When creating the pattern pieces and adding the seam allowances, do I need to add the 1/2in seam allowance to the outer brim edge, or just to the edges that will be sewn together?
Hi Anna,
If you’re adding seam allowance to this pattern, add it to every piece! I have done this and found it contributes better to the size proportions if you keep it consistent.
Crafty regards,
Anna F.
Spoonflower
I’m confused, I’m finally coming around to test this hat. I’ve already cut it last year but only sewing it now as I have time. So you’re suggesting that I should’ve added 1/2” seam allowance prior to cutting or is there already a 1/2” s/a already on the pattern?
Hi there,
Based on reviewers we found that including a 1/2″ seam allowance may contribute to better sizing for this particular hat. I have made plenty of these bucket hats that sold just fine at local craft markets without adding the seam allowance, so it’s all up to preference. Happy to answer any more questions you may have, thanks so much for your comment!
Crafty regards,
Anna
Spoonflower
So, what size is this pattern for? Adult small, adult medium? etc.?
Hi Joan!
This hat is for an adult; the circumference of the hat in the pattern is about 23 inches (58.5 cm). There are instructions in the post for how to decrease the size if the printed version is too large of a dimension for the head you’re making the hat for.
Best,
Betsy
Spoonflower
Just downloaded your bucket hat pattern, does the pattern allow for a seam allowance, or do I have to add my own.
Hi Ann, great question! We recommend adding 1/2″ seam allowance on your own as you cut the pieces of fabric. This post has been updated (in step 1) to mention that.
Crafty regards,
Anna
Spoonflower
I made sure to measure 1/2″ seams and when I went to attach top it was almost an inch to small. What did I do wrong? I am an experienced sewer.
Hi Mary,
Very sorry you’re experiencing some sizing issues! If your fabric has zero give and cannot be worked around the perimeter of the top, I would increase the size of the top pattern piece and recut for this particular hat. I have been meaning to make another bucket hat so I can update this tutorial with the best instructions and photos– thank you so much for your feedback, I will revisit the pattern and seam allowances and see what helpful updates can be made.
Crafty regards,
Anna
Spoonflower
I want to enlarge the size of the cap. How do I do that?
Hi Maxine,
Great question! You can increase the size of the hat just by redrawing the pattern! Take the original pattern in this blog post, cut the three pieces out, then lay each piece down on top of another sheet of blank paper. You’ll then trace around each piece with a marker/pencil, but extend the whole border about 1/4-1/2 inch. Now you have a bigger pattern you can cut and use! You can keep adding more to your extension measurement depending on how big you need the hat to be, or take in the border for a smaller size like for a baby or toddler. This method should increase the size of the whole hat, but if you find the brim that goes above your eyes is too large you can always trim the outer edge before finishing.
Crafty regards,
Anna
Spoonflower
Could I use faux fur?
Absolutely! I’ve used our Minky fabric to make a soft and fuzzy bucket hat, I assume faux fur would be the same concept but definitely take into consideration the thickness of it as you’re sewing! You might need to up the size of the pattern if your fur is really thick especially if you decide to use it as the inner layer.
Crafty regards,
Anna
Spoonflower
2 fat quarters weren\’t enough……
Hi Kiara,
Very sorry that the suggested fabric amount did not work! This tutorial uses two fat quarters of our Lightweight Cotton Twill which measures a little wider than the traditional fat quarter (29 inches wide vs. 21 inches). We have tested the bucket hat pattern a few times using this fabric with that width and was able to complete the project.
Again I’m sorry that the post was not clear about this– I have added a note about it in the materials section.
Best,
Anna
Spoonflower
I can’t wait to make this! would Cypress cotton canvas also be good?
Hi Amanda,
Yes, Cypress Cotton Canvas would be a great choice! That’ll make it a bit sturdier, too.
-Anna
Spoonflower
I just made this hat. It doesn\’t seem as tall as the one in the picture. Should I have added on 1/2 in all around for seam allowance when cutting?
Adding seam allowance when cutting your pieces may be a good idea next time! If you still find your hat is too small, you can add another half inch or more of seam allowance or modify the pattern by adding height to the crown piece.
Happy sewing,
Anna
Spoonflower
Can’t wait to get started.
Love this…such a fun project! I added 1/2” to the depth of the hat and took a tiny bit of the flare out of the brim, and it was perfect.
Oh! How do you remove some of the flare? I’m new to altering patterns, and I keep making the brim too short to match up with the crown when I try to remove some flare. I love making the hats…but then won’t wear them because there’s too much floppy flare. LOL Thanks!
What Anna said below…but just to be clear, you need to keep the short curved edge intact because it matches with the hat. You’re basically cutting a small triangle off of the short/seam edge of the brim (so the length of the long edge is reduced). It only takes a little bit…1/4” to 1/2” on the bottom of the triangle piece.
I’ve made a bunch of these now as gifts, and they are a big hit!
Hi Raine,
You can make a less-flared bucket hat by trimming down the longest curved edge of the brim pattern piece. I recommend starting with 1/2″ or even 1/4″ at a time until you reach your desired size.
Happy sewing!
Anna
Spoonflower
Hi, thanks for this pattern. What is the finished circumference of the hat?
Hi Marsha, great question!
This bucket hat’s circumference is about 23 inches (58.5 cm).
Best,
Anna
Spoonflower
Aloha y’all…
just the sort of thing I need for myself, AND for a reunion we’re having on Maui. I’ll make a few to give out as gifts… (grin) … well… MAYBE… IF I have time. I’m also building a video set to give out as well…
SO much fun… and SO little time. . . (grin)
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Until that time. . . Earl J.
Great project!
Love it!
Your pattern indicates that you need 2 x outside and 2 x inside for the top. Should that be 1 x each?
Hi Barb,
Yes, you’re absolutely right! Thank you for pointing this out. We’ve updated the pattern with the correct numbers.
Best,
Anna
Spoonflower