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How to make a sun hat

Set sail on a seaside adventure with this summer sunhat sewing pattern. Kirsty Hartley shows you how to make a sun hat!

How to make a sun hat

Make a DIY sun hat for girls and boys with our step-by-step guide, or if you fancy making a sun hat for yourself too, simply enlarge the hat template for the biggest size by around five per cent. Kirsty Hartley will show you how to make a sun hat with her tutorial.

If you’re new to sewing then head to our beginners guide to sewing which will show you all the basics. We also have the top sewing machines for beginners if you’re in the market for a new machine. 

Materials

You’ll need to download our sun hat template before learning how to make a sun hat!

Sunhat sewing pattern sizes

How to make a sun hat

How to make a sun hat
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You Will Need

  • Cotton fabric
  • Fabric scraps
  • Ribbon
  • Basic sewing kit

Total time:

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.

How to make a sun hat step 0

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.

How to make a sun hat step 2

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.

How to make a sun hat step 3

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 (116in) 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.

How to make a sun hat

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 (158in) 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.

How to make a sun hat

Step 3

Press the long edges under by 1cm (38in) 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.

How to make a sun hat step 1

Step 2

Unfold the binding and turn one short end under by 1cm (38in). 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 (38in) 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.

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We hope you’ve enjoyed learning how to make a sun hat! For more projects head over to our sewing patterns for beginners which has a whole host of easy makes. If you’re looking for something to fuel your sewing obsession then check out The Great British Sewing Bee Episode Guide which gives you all the gossip behind the show. 

How to make a sun hat