Instructables
Here's a pattern and instructions for two styles of brimmed hats with crowns made from six identical pieces. I like to make these from reclaimed materials. The orange one used to be two shirts, and the brown one used to be two handbags. Once you've made a couple, you can throw one together in about 45 minutes.

The brims are made of plastic rescued from the packaging for a dress shirt. Other possible sources are plastic spiral notebook covers (not the cardboard ones, though) or blister packaging if the product is big enough to have about 6" x 4" of flat (or gently curved) plastic. The smaller brim would probably fit on a plastic milk or juice jug.

The orange one has a zipper on the crown under which you can put any kind of Sekrit Surprize. The zipper was part of the neckline of the original shirt, which I cut to fit. I also like to put pockets on the crown, as I did with the brown one.

This tutorial shows the construction of the brown hat as I'd already made the orange one. However, the technique is almost exactly the same for both, just the pieces are slightly different sizes.
 
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cglaw20131 year ago
outstanding
I used the orange hat pattern with the brown hat bill to make a Mario hat for my son's Halloween costume out of craft foam and hot glue.
mario hat.jpg
Ha ha OMG I love the Mario Hat idea! Great Job!
Thanks for a really well done instructable - I'm fairly novice with the sewing machine and my hat turned out great!

new teal hat.jpg
Foaly74 years ago
Somebody needs to make a flexagon hat, that's sorta reversible, but is more than two hats in one.
 I love that style of hat but they cost too much to buy a nice one.
I wish I could sew but many of my gender is missing that gene.
Good instructable.
No - your personality is missing the "give it a try" attribute. So give it a try. I'm trying to add a brim to an existing beanie, and doing it by hand sewing too.
rachel (author)  iamunique1274 years ago
What, the male gender? Nonsense!  Check out the great work done by men in making some of my other hat instructables.  You can do it if you want to!
LionessQB4 years ago
Are there any pictures from someone making the Orange hat?
kjbrasda4 years ago
If you can't find suitable plastic to reuse for the brim, I've found that plastic stencil blanks work great. I made a few more to donate to cancer patients through my mom's art group, including one I modified the pattern for to make it brimless and reversible.
I have been looking EVERYWHERE for a hat pattern like this. This is EXACTLY what I wanted.  I am almost finished with the orange hat pattern, and while I am a bit confused in some areas of the directions, I am managing to get it right (and I'm a very experienced sewer).  I love the way it looks!!!!  Thanks, Rachel. This is AWESOME!!!  I'm making one to match an Amy Butler (www.amybutler.com) dress I have in progress! 
solusetal4 years ago
I am going to be making more than one of these.  I wear hats all the time and like this style. 

Shouldn't the carpenter's rule be stated "measure twice and cut once"?
kjbrasda5 years ago
thanks for the excellent tutorial!
I made me one from some awesome fabric I just *had* to have when I saw it in the store. I think I'm going to redo my chuckies in the same stuff. lining is small yellow checks

I also made one for my brother and one for my daughter.
http://kjbrasda.deviantart.com/art/hats-112828422
the green one was heavy woven stuff that was a bit hard to work with, the blue a shirt my daughter couldn't wear because ithe fabric was uncomfortable on her skin, ok as a hat though! That fabric forced me to use interfacing for the first time, as it was a bit light and floppy for a hat on it's own.
06092009017.jpg
rachel (author)  kjbrasda5 years ago
awesome! thanks for the pix, those look great.
kjbrasda rachel5 years ago
thanks!
oh yeah, I made one for my sister too, no pic, but it's black and white plaid with two little bows on pins next to the brim, lining black with pink polkadots.
Kaiven5 years ago
LOL. I always put needles in the "wrong" way xD It is always hard to remove the pins, and I end up screwing up the stitching.
Tulumayan5 years ago
A million THANKS for posting this. I had a book from grade/high school (1970's) that is long since gone explaining how to do this. I made a few hats and remembered some of it but you filled in all the empty spots. I sure do appreciate it. My little GRANDSON is going to have some awesome hats now.
bigmark5 years ago
I cannot weight to make one,Mine will be red like super mario. lol for the kids(& me too)lol thanks
zzoe5 years ago
Made a hat like this years ago. Old BDU material, oilskinned with Sno-Seal. Wore it for years and LOVED it. Lost the hat, lost the pattern. Sad Zzoe. Now thanks to you sad Zzoe is HAPPY Zzoe. Soon i will make one! THANKS!!!
Indie5 years ago
Here's my attempt! I did a little bit of modification -- I used the brown hat pattern, but I made the brim smaller (trimmed the plastic stiffener at the front so that it doesn't stick out as far) and I covered the brim in the same material as the rest of the hat (trouser-weight corduroy). I also skipped the band lining step and just sewed a ribbon around the inside to cover up the raw edges. Thanks for the design -- I finished it in under three hours, and it makes a really spiffy hat that people don't believe is homemade.
hat1.jpghat2.jpg
rachel (author)  Indie5 years ago
That's gorgeous, thanks for posting the pics! It looks great on you too. Isn't it fun to tell people who ask where you got that great hat, that you made it?
Alathald6 years ago
Very cool hats, for the patterns in step two you may want to try out Inkscape, it will allow you to make minor adjustments to your lines while you draw without it being a big hassle. GIMP is great for photos and such but for things like cartoons or patterns (any type of linework) Inkscape is the winner.
http://www.inkscape.org/
tarziesgirl6 years ago
Well, its my first comment, and my first comment with pictures, so here are the pictures after the second attempt.
hat1.jpghat2.jpg
rachel (author)  tarziesgirl6 years ago
Hey, that looks fantastic! Nice job!
tarziesgirl6 years ago
Rachel, I finished it! I went back and reread, and reread. Then I took out all of the sewing I did wrong for step 9, and did it again. I want to add a button to the top, but I took pictures to share. I made it for my son for Christmas. I know he'll love it. Thanks so much for providing this instructable with pattern! Oh, and I couldn't resist showing off my old sewing machine with the pictures, I just love my treadle. Erin
just make it red and stick an M on it and you could have a seriously sweet mario hat!
LaxLovaLV7 years ago
The links aren't working. Might be my computer but if you could check the would be GREAT! I can't wait to start this project!
rachel (author)  LaxLovaLV7 years ago
Thanks for catching that, I fixed them. Promise to post pictures, I'd love to see your version of these hats!
Admirabilia7 years ago
I like your hand drawn pattern and consice instructions. Thanks for this, its a good reminder to K.I.S.S... Looks good, I think we oughta stake out a millinery section Fo Sho!
rachel (author)  Admirabilia7 years ago
I like it, a millinery group. Maybe some instructables on woven straw hats, maybe felted ones, maybe some based on hat forms... witch hats, toques, pillboxes... I anticipate comments like, "WAIT wats' is milllienrey N-E-way??"
jeffreyf7 years ago
Can you make these out of denim? Because if so, you could have some serious 70's Dolemite action going on.
Thanks for posting this! I'm not sure my beginner sewing skills will be able to handle it, but I've got some old denim that I think would make a nice hat.
Very nice. I'm glad you posted this, I've always wanted a hat like this. Now I can make one.
SurferGeek7 years ago
Huggy Bear would be proud! ;)
Jezza Bear7 years ago
Wow, I don't know what took longer, the hat making or the Instructable :-) Great modelling at the end, who is she? Get her manager on the phone now :-). Not quite my style but I know my girls will be interested.
jeffreyf7 years ago
Excellent Instructable, complete with excellent final picture!