Step 5: Construct the lining

Stitch the lining pieces together. They're kind of like pie slices, if you ignore the curving parts near the wide end. For your first hat, do the lining first to get a feel for the curves of the crown. Otherwise you can do the main pieces first and then the lining, it doesn't really matter.

You may be tempted to stitch them together in pairs and have three fat pie slices, but resist that. Stitch two segments together, then add a third, for half a pie. At this point the temptation is to add a fourth segment (and then fifth, etc) but don't do that either. Stitch the last three together just like the first three, so that you have two half-pies.

You can then sew the final seam, which will now be one straight line. Trust me that you do not want to try to stitch the sixth piece of a pie in place around the point of it. Even the last third is difficult - going around points is just Hard and there's no need to do that here.
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.<br />
Ha ha OMG I love the Mario Hat idea! Great Job!<br>
Thanks for a really well done instructable - I'm fairly novice with the sewing machine and my hat turned out great!<br><br>
Somebody needs to make a flexagon hat, that's sorta reversible, but is more than two hats in one.
&nbsp;I love that style of hat but they cost too much to buy a nice one.<br /> I wish I could sew but many of my gender is missing that gene.<br /> Good instructable.
No - your personality is missing the &quot;give it a try&quot; attribute. So give it a try. I'm trying to add a brim to an existing beanie, and doing it by hand sewing too.
What, the male gender? Nonsense!&nbsp; Check out the great work done by men in making some of my <a href="www.instructables.com/id/Checkpoint-Charlie-Hat/#DISCUSS">other hat instructables</a>.&nbsp; You can do it if you want to!<br />
Are there any pictures from someone making the Orange hat?
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&nbsp;for to make it brimless and reversible.
I have been looking <strong>EVERYWHERE</strong> for a hat pattern like this. This is <strong>EXACTLY</strong> what I wanted.&nbsp; I am almost finished with the orange hat pattern, and while I&nbsp;am a bit confused in some areas of the directions, I am managing to get it right (and I'm a very experienced sewer).&nbsp; I love the way it looks!!!!&nbsp; Thanks, Rachel. <strong>This is AWESOME!!!</strong>&nbsp; I'm making one to match an Amy Butler (www.amybutler.com) dress I&nbsp;have in progress!&nbsp; <br />
I am going to be making more than one of these.&nbsp; I wear hats all the time and like this style.&nbsp; <br /> <br /> Shouldn't the carpenter's rule be stated &quot;measure twice and cut once&quot;?<br />
thanks for the excellent tutorial!<br/>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<br/><br/>I also made one for my brother and one for my daughter. <br/><a rel="nofollow" href="http://kjbrasda.deviantart.com/art/hats-112828422">http://kjbrasda.deviantart.com/art/hats-112828422</a><br/>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.<br/>
awesome! thanks for the pix, those look great.
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.
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.
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.
I cannot weight to make one,Mine will be red like super mario. lol for the kids(& me too)lol thanks
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!!!
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.
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?
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.<br/><a rel="nofollow" href="http://www.inkscape.org/">http://www.inkscape.org/</a><br/>
Well, its my first comment, and my first comment with pictures, so here are the pictures after the second attempt.
Hey, that looks fantastic! Nice job!
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!
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!
Thanks for catching that, I fixed them. Promise to post pictures, I'd love to see your version of these hats!
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!
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??"
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.
Huggy Bear would be proud! ;)
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.
Excellent Instructable, complete with excellent final picture!

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Bio: I run Neal's CNC in Hayward, CA, an expert CNC cutting and fabrication service. Check out what we do at http://www.nealscnc.com ... More »
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