How to make a sun hat: Cutting out
Step 1
Trace the pattern for the hat segments and brim following your chosen size lines.
Step 2
Place the hat segment pattern on your fabric and draw around it, adding a 5mm (¼in) seam allowance. Cut six hat segments from the main fabric for the hat outer and six hat segments from the inner fabric for the hat inner. Or, use a mixture of fabrics, using a different one for each segment.
Step 3
Cut one hat brim from the outer fabric and one from the inner fabric, adding a 5mm (¼in) seam allowance to the inner and outer edges.
Step 4
Mark the notches from the pattern to the inner circle of both pieces. This will help you align the pieces accurately before sewing them together.
How to make a sun hat: joining the hat segments
Step 1
To make the hat outer, take three outer segments and stitch them together down the curved edges. Repeat for the other three segments to make two halves of the hat. Press the seams open.
Step 2
Fold the ribbon in half to make a loop and pin the two ends to the centre of one half of the hat, matching raw edges.
Step 3
Sew the two halves together, trapping the folded loop at the crown.
Step 4
Repeat to join the six inner hat segments together but without the loop.
Step 5
Place the hat outer and hat inner WS together and stitch all the way around.
How to make a sun hat: Attaching the brim
Step 1
Take the brim sections and carefully snip into the inner curve by just 2mm (1⁄16in) only. This will release the curve as you sew the brim into place.
Step 2
Pin the outer brim RS together with the outer joined hat segments. Stitch together all the way around, taking care to match notches at the sides.
Step 3
Repeat to stitch the inner brim RS together with the inner hat, using your original sewing lines as a guide.
Step 4
Press the brims away from the hat, trapping the seams between them.
Step 5
Topstitch around the brim 5mm (¼in) from where it joins the hat segments, to flatten it.
Step 6
Pin then sew the outer brim to the inner brim all the way around the outside edge. Trim the edge if necessary to neaten so it’s ready for binding.
How to make a sun hatL:Making the binding
Step 1
Cut a bias strip of fabric, or several lengths which are cut at a 45-degree angle to the selvedge. You will need approximately 100cm (40in) cut to a 4cm (15⁄8in) width. Cutting fabric on the bias is an excellent way to finish a curved edge as the fabric has a little stretch to it when cut this way.
Step 2
Stitch the strips together, if necessary, at a 45-degree angle.
Step 3
Press the long edges under by 1cm (3⁄8in) to the WS.
Step 4
Press the binding in half WS together, encasing the folds.
How to make a sun hat: Attaching the binding
Step 1
Measure carefully around your hat outer brim edge. Cut the pressed binding to this length, adding 5cm (2in) extra for ease and turning.
Step 2
Unfold the binding and turn one short end under by 1cm (3⁄8in). Place one unfolded long edge RS together with the brim inner, matching raw edges. Stitch together all the way around along the opened fold. When you reach where you started, overlap the other short end by 1cm (3⁄8in) and trim.
Step 3
Carefully fold the binding over and around to the hat brim outer and stitch this into place. This can be a little tricky, so take your time. You may find it easier to tack and ease it into place first before you stitch. You've officially learn how to make a sun hat.
