Fast forward years of testing (and my kids outgrowing the smallest sizes) - and here's my new bucket hat pattern. It comes in 5 sizes and it's free.
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And it gets even better: this is a reversible bucket hat - no raw seams exposed. Yay! Thousands have sewn up this pattern so far, join in!
Want a printer-friendly option of the whole tutorial without ads? See the ' optional PDF file.
Whether you're headed to the beach, working in the garden, or just going outside in the warmer months - this reversible hat is a must-have.
I want to help you make your own bucket hat in the size you need, the color you want, and the fabric you choose. Are you with me? Read on, below is an easy bucket hat tutorial with a free printable bucket hat pattern waiting for you - in 5 sizes!
Here's why I love this free pattern for bucket hat - and why you might too:
And, readers say this might be the best step-by-step tutorial on how to make a hat. (Seriously. Daily, I get emails from people that are NEW to sewing, saying it was way easier than they expected.) - Meaning YOU can sew it too!
And here it comes ... another cute hat photo. I'll be bold and say this might be the best free bucket hat sewing pattern out there. After all, it's been tested and tweaked for years, by a person who's pretty picky about store-bought stuff haha!
These reversible bucket hat sizes are a bit on the smaller side. In doubt, choose a larger size. It's better not to go too small as the hat will always shrink a little after a few washes. Also, it should be comfortable. And see sizing tips at the end of this diy hat tutorial.
First, I need to admit that a classic bucket hat project might not be easy to sew, especially not for beginners.
But I'll show you how I used a shortcut, to make the project way easier. It's a different construction process, differing from the industry-standard procedure in sewing a bucket hat.
The result will be the same - but sewing will be way easier. Are you with me?
Gather these supplies before you start sewing the bucket hat:
Shop my personal favorite sewing supplies on Amazon HERE.
The seam allowance for this project is '" inch (1cm). This free pattern for bucket hat comes in 5 sizes, so you'll first need to decide on the size you want to sew.
After you've decided on the hat size, use the paper pattern (see note above) to cut out these pieces from fabric:
And here's a little image to help you visualize the pattern layout. Here's what the parts of the hat are called in this tutorial:
And this is the way to place your pattern on the fabric when cutting:
You'll end up with two identical sets of pieces, one from Outer and one from Lining fabric.
Make sure to mark the pieces - make tiny notches in the center of all Sides and Brims and transfer the markings from the Crown pattern piece. This will make your sewing so much easier later on:
Pair all the Brim and the Side pieces, placing each pair with the right sides together and pin.
With the right sides together, sew all the short edges together, using a '" or 1 cm seam allowance. You get 4 circular (slightly oval, actually) bands, two full brims and two full sides:
Press all seam allowances open.
Now, let's make one color first: the Outer. Take the 'Sides' circular band and the round Crown piece.
Cut tiny notches, slits into the fabric on the shorter raw edge of the Sides piece to make the pieces match. I clipped tiny notches approximately ¼" (½ cm) into the seam allowance. Take your time. Then pin or clip the two pieces together:
IMPORTANT: the double-notch mark ('W' mark) on the oval Crown piece means the FRONT and the BACK of the hat. Align the double-notch ('W' mark) with the seams on the Sides piece.
And here's another photo for those who prefer pins:
From here on, it just gets easier: just sew all the way around, using a '" or 1 cm seam allowance:
Then press the seam allowance towards the Sides and top stitch around for a nicer look. Feel free to use whatever distance from the seam you prefer - anything between '" and ¼" (3-8 mm) should work just fine.
The top of the hat will look so professionally made!
Take the Brim piece and pin it to the cap with the fabric right sides together. Again, match the notch markings. Also, it will help you a lot if you cut tiny slits into the narrower part of the Brim piece - just like you did above with the Crown piece.
Then sew around using a '" or 1 cm seam allowance:
To make the seam look prettier, press the seam allowance towards the brim and topstitch the Brim, like you did in Step 5:
Repeat the steps with the Lining fabric pieces, and you've got yourself these two identical parts of your soon-to-be bucket hat:
Now turn it right side out through the opening and you've basically made it!
Press the brim so you get an even outer edge. Sew the opening closed or proceed with the next, finishing step.
Now, the only thing left to do is to topstitch the brim for stability. See the lines all the way around the edges of the brim on the completed hat? Sew circles around the brim to add stability to the brim.
I used the edge of my machine sewing foot to eyeball the distance between the seam lines, but I never demand perfection from myself. 5 or 6 rows will give enough stability to the brim - even if sewn with quilting cotton, like all these in the tutorial. You can mark them using a fabric pen, spaced ½" or '" apart.
But honestly, I never have the patience to mark. Hence the wiggly seams. I simply call them a 'feature'. LOL
Good job, you've made it through! And if you liked this easy bucket hat sewing project, share it in your favorite Facebook group - or join ours to show when you sew one up!
I want to help you make the best diy bucket hat, and a little help goes a long way!! Here I'm answering the most frequent questions people ask me about sewing this hat:
For more information, please visit neon pink bucket hat.
I decided to put down ½ yard per print in the supplies section, making it a total of 1 yard.
But you can get away with way less fabric if you rearrange and turn pattern pieces for the most economical use of the fabric, with the least leftover possible.
This way, you could even squeeze two hats out of a yard/meter of fabric! But be cautious, as the different cutting could cause the fabric pieces to shrink in different directions once washed. It could distort your bucket hat form. And this is why it's good to use a bit more fabric to ensure the same direction, 'grainline'.
Quite a few readers have asked me how to make a bucket hat with a ponytail hole at the back, to keep those long hair off the neck in the hot summer sun.
A diy bucket hat with a ponytail hole is a great idea, and I have an easy diy addition to this tutorial on my mind already! I've put it on my to-do list. However, if you'll be attempting this with AppleGreen Cottage bucket hat pattern, please note that the ponytail hole needs to be located at one of the VERTICAL seams of the Sides piece. Which - makes it even easier! I'm itching to try this option! I'll be making a tutorial for a discreet slit at the back of the hat on my pattern. Get ready for a bucket hat featuring a clever little ponytail slit to keep hot hair off your kids' little necks!
Bucket hats should first and foremost be comfortable. If your hat sits too tight, you may feel some tension, and that's too small. Also, it depends on thick your hair is: think a bucket hat on a shaved head versus a hat on a head with thick, voluminous curly hair! That's good to consider - along with measuring your head circumference before you start sewing.
Also, natural fibers in hats can cause gradual shrinking over time. Cotton will shrink, especially after several washes. This is why I've designed this bucket hat pattern a bit larger than usual. I've made my portion of too-small hats, and now, I'd rather make it a bit larger and toss it into the washer (and, if needed, even dryer!!) to get it to the 'final' size.
And one last thing I learned (many times!) about a child's head: it grows fast, so make sure to sew one hat more - in the next size for your kid. This way, you'll have their next favorite summer hat ready for when they outgrow their current hat.
Please note that this pattern has been thoroughly tested for years (and used) before I made it free as a gift to everyone visiting AppleGreen Cottage. 2 reasons why the sizing on your sewn bucket hat could be off:
1 - Select the right pattern size by first measuring the head circumference of the person who'll wear it. If you are unsure what size would fit you, go for the larger of the two you are considering.
2 - Please bear in mind that the hat should be comfortable. If you want a tight fit, go for a smaller size, but it's better not to go too small as the hat will always shrink a little after a few washes.
3 - Use the exact seam allowance as indicated on the pattern pieces. Please note that since thousands of people have been using this pattern, I've come to realize that sometimes, one could easily forget to follow the exact seam allowance listed in the pattern:
It's all in the brim ' You can either keep the brim turned somewhat down, or you can turn your brim up in the front to reveal more of your face - that would result in a more casual bucket hat look. You can dress it up by pairing it with an elevated outfit, or you can match a bucket hat with your casual clothing (THIS!). Have fun!
Now go, make one pretty bucket hat for yourself, and then for all your loved ones. Super popular with kids, especially if mixed with their favorite prints. (Dinos, anyone?) Also, it makes a perfect men's bucket hat too.
Now you can start making your own stylish diy hat collection - I want to see all the cute bucket hats you make! No time to sew now? Save this diy bucket hat pattern and tutorial for later, so you can get your own pdf file any time.
The majority of people love spending times outdoors. It could be that you love going to the beach, hiking in the mountains, going for a leisurely walk, surfing, or doing something equally as active and enjoyable. Basically, it doesn't matter which outdoor activities you do, but one thing's for sure, you'll get plenty of sun exposure.
Sun exposure (to some extent) is important; it's a way that you can get vitamin D naturally, but prolonged sun exposure can lead to sunburn, premature skin aging, skin damage, skin cancer, heat stroke, cataracts, and even uneven pigmentation.[i] Many people think sunscreen is enough, but it's not. These days it's absolutely essential you take all the necessary precautions to avoid such things while still being able to safely enjoy the sun and the outdoors.
It doesn't matter whether you're outside for just 20 minutes or a few hours, wearing a sun hat is a must, and guess what, it doesn't even have to be a sunny day to justify wearing one because it's still possible to get burned when it's cloudy out.[ii]
In saying all of this, despite sun hats being an absolute necessity, some people get it oh so wrong when buying a sun hat'
1. Is It Rated?
There's no doubt about it before you begin to even think about how good your sun hat looks on you, you've got to consider how much protection it offers.
Look for a hat that has a UPF (Ultraviolet Protection Factor) rating. The rating should be at least 30+, but realistically it needs to be 50+. If you're wondering what a UPF rating is, it's a rating system that allows the measurement of how much UV radiation is let through the fabric. If the fabric has a UPF of 30+, approximately 96 percent of UV radiation is blocked while about 99 percent is blocked with a rating of 50+.[iii]
2. How Big Is Your Brim?
When choosing your sun hat, you'll also need to look at its brim. You can opt for a sun hat with a large brim, which is perfect if you're just hanging out outdoors and not really moving too much. There's also the option of a cap, which can suit many outdoors activities.
The boonie hat, a cousin to the bucket hat, has been a favorite sun hat for fishermen, beachgoers, and hikers for some time, and it's really no surprise given the many benefits of a boonie.
3. Is There Any Breathability?
Wearing a sun hat to protect and cool yourself down on a hot day is necessary, but if it doesn't have any breathability capabilities it can also heat you up.
Make sure your sun hat is made out of a breathable fabric. This will ensure you won't overheat in the hotter months when the sun's beating down.
4. Is It Comfortable?
Your comfort should also be taken into consideration when selecting a new sun hat. It has to be comfortable for all the different activities you'll be using it for. Hats with a medium to small brims, such as the bucket hat, are the most versatile sun hats on the market. For example, if you're looking for a sun hat for climbing, a bucket hat will allow you to look up and see your route ahead without the hat hitting your back and falling off never to be seen again. Or if you're going to use your sun hat for running, it needs to be super-light, breathable and secure, so it doesn't fly off your head when you're running in the wind.
A sun hat fit is equally important ' it must fit properly! A poor-fitting sun hat that is too tight will end up leaving you with constant headaches and a loose one will impair vision, be unstable, and of course, you've got more of a risk of losing it.
5. Is It Durable?
A good quality sun hat will last you a very long time. If your sun hat could speak, it'd have many tales to tell. And, if you're really active and love to be outdoors, your sun hat will become your trusty companion ' this is why durability should take precedence!
Many of the sun hats that are sold are light-colored. The idea behind using light colors is that a light color such as white or beige help reflect heat. But one thing you have to remember is that a light-colored sun hat is likely to get dirty and stained easily, meaning you'll have to replace your sun hat more often.
A good sun hat is made out of quality material, with quality sewing. So keep your eyes peeled for woven sun hats as woven construction is known for its strength and durability.
6. What Does It Look Like?
Of course, style is still important. You want to impress and feel great in your clothes and accessories, and the same goes for your trendy bucket hat. Look for something that suits you, and look for the colors that compliment you; because regardless of what they say, looks do matter!
The Womens Eclipse Newsboy Draped Beanie Knit Cap with its realistic water prints by Aqua Design is both fashionable and versatile.
Life's all about enjoyment and that includes spending plenty of time outdoors whether it is by the sea or river. Look great outdoors and remain protected at the same time, so stay calm and wear your hat!
Visit Aqua Design to see their whole collection of active wear for men and women.
The company is the world’s best custom design 5 panel hats supplier. We are your one-stop shop for all needs. Our staff are highly-specialized and will help you find the product you need.