Step 6: Make a Brim (the Threadbanger Way)

To make the brim I follow a tutorial created by Threadbanger and found here. Because their tutorial is so great I won't go into too much detail here, but basically I traced the brim of another hat onto some construction paper (which gives a nice flexible brim). To get the depth of the brim I measured my other hat which was a little over 1.5" and freehand drew the inside shape. I then folded the paper at the midpoint and cut it to ensure both sides are the same.

After cutting out the shape I covered both sides in duct tape and then traced out and cut two pieces of fabric 1/2" larger than the brim. When cutting out the fabric make sure to cut straight across the back edge (don't follow the inner curvature of the brim pattern).

Pin and sew the two pieces of fabric together along the curved front edge and flip it around so the stitches are inside of what is now a pocket.

Place the paper brim inside the pocket and pin and sew along the back curve of the brim making sure that the fabric is pulled tight from front to back before pinning.
I'm in the army cadet force but in Wales! Much more disciplined then the American cadets.
<p>I survived Rookdom in the Norwich University Corps of Cadets. Norwich is located in Vermont. Wales has never seen snow like Vermont. Wimps! :-)</p>
Great hat! I make hats but never thought of using fleece for a more structured hat. My daughter will love this. I'll make her one in camo fleece this weekend. Thank you!
What is that cutting tool called?
it is just a rotary cutter... these can be picked up at any arts and crafts store and are great for cutting fabrics like fleece
If you buy a rotary cutter you may also want to invest in the proper cutting mat, like the author uses in the photos. It looks like a Fiskars brand mat. Olfa is another brand. They are most often found with quilting supplies. Using the mat will GREATLY prolong the life of your cutting blade as well as protect your table, Quite often you can buy a small rotary cutter with a mat in a &quot;travel quilting kit&quot; for a reduced price. If you plan on learning to sew and doing a lot of sewing buy the largest mat you can easily afford. I started with a small mat and immediately regretted not getting the larger one. <br> <br>If you live in the USA and live near a Joann's or Michael's 40% off coupons are commonly available.
and did you use cardstock for the brim or something? and was it pretty sturdy?
yes, it was just cardstock... I wanted a pretty lightweight and flexible brim... if I were to make this hat again I would probably purchase a plastic brim insert from a craft supply store and just cut it down to size.
I have used iron-fusible stiff interfacing, like Pellon Peltex 72F for hat brims. You can buy it at fabric stores like Joann's or Hancock's. It's great because it's washable. I also know some people use milk jug plastic for brims.
can this be adapted for duct tape?
Really great job - I'm going to try this. Would it be possible to see a photo of the whole hat inside out? And maybe a close-up of the stitching. I need all the help I can get, thanks, g_g
thanks for the comment, unfortunately I gave this hat away to my bandmate and so I can't take any more close-up photos. The stitching is all pretty basic straight stitch (no zigzagging) and the spacing really depends on the material you use (fleece needed about a 1/16th inch spacing I think). Hope this helps!
OOOOHHH! I will try it
wow! looks really nice. great job!!
That's some great work man, keep it up. -Duck

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