Introduction: Round Pillbox Hat

Picture of Round Pillbox Hat

I went to visit my daughter recently and we made these cute Pillbox hats. You can make one in a very short time and they can be left plain or decorated in a variety of ways.  The beige hat was decorated with a satin ribbon and large silk flower on the side. The white pillbox hat was covered with silk flowers petals that I glued all over the top and sides. It was a 5-1/2" circle for the top and 1-1/2" height.

Step 1: Supplies

Picture of Supplies

Sewing machine
mini glue gun 
mini glue sticks
straight pins
measuring tape
cereal box
3.2 mm cotton cord for piping
1/3 yard fabric or old skirt

Step 2: Cut Up Cereal Box

Picture of Cut Up Cereal Box

To make the basic shape of the hat, cut out a 6" circle out of paper for the pattern. On the back of the cereal box, trace around circle. Repeat for another circle, but on one of the circles, add 1/2" all around for the tabs.

For the side of the hat, cut a strip 1-3/4" x 24", You may need to glue 2 strips together until you have a strip that is at least 24" long. 

Step 3: Glue Side of Hat to Top of Hat

Picture of Glue Side of Hat to Top of Hat

Fold tabs up and with glue gun, glue tabs to one of the long edges of hat band. When you have all of the tabs glued to the strip, over lap side strip and cut off excess. Glue ends of strip together. This is the basic foundation of the hat.  

Step 4: Cover Hat With Felt

Picture of Cover Hat With Felt

Place 6" cardboard circle onto felt and trace around. Cut out felt circle. Glue onto 6" cardboard circle. Cut felt into 1-3/4" strips. Glue onto side of hat, do not overlap the felt.  

Step 5: Glue Fabric Onto Hat

Picture of Glue Fabric Onto Hat

Cut a piece of fabric 4" wide x 25" long. Glue onto side of hat. Fold under 1" and glue on the inside of hat. Fold 1" over the top edge of hat and glue down.  Cut a 8" circle of fabric and place it right side down. place the felt covered cardboard circle on top of fabric, felt side down and bring the edges up over the cardboard and glue down.

Step 6: Piping

Picture of Piping

Cut a strip of fabric 2" x 27". Cover cotton cord with fabric. pin. stitch with sewing machine. Trim excess fabric. Glue piping around top edge of hat, tucking in ends.

Step 7: Top of Hat

Picture of Top of Hat

Glue 6" fabric covered circle to the top of hat.

Step 8: Loops for Bobby Pins

Picture of Loops for Bobby Pins

Using embroidery floss, finger crochet 15 single crochet stitches. Do this 4 times. These are the loops for the bobby pins. Glue these to the inside of the hat, 2 on each side. allow 1/4" of loop to  stick out below hat band.

Step 9: Lining

Picture of Lining

For the lining, cut a 7" circle of fabric. Cut a strip of fabric 3-1/2" x 25". sew the short ends of strip together with 1/2" seam allowance. Pin circle of fabric to this and stitch together.  Trim excess seam allowance. Using a hot glue gun, glue the lining inside of hat, turning under 1".

Step 10: Fabric Flower

Picture of Fabric Flower

Cut a strip of fabric 3" wide x 30" long. Fold in half lengthwise and, with a running stitch, gather cut edge to about 10" Roll up gathered fabric, securing with a few stitches as you roll. Hand sew and continue rolling until the entire strip is rolled up and sewn together so it will not come undone. Glue the fabric flower to the side of the hat, covering the seam. Now, wasn't that easy? Wear your new pillbox hat with a simple shift dress and a string of pearls.  


N_Ransom made it! (author)2015-08-01

I've had this tutorial saved for ages, along with a Cheerios box I bugged my mum for, finally got around to doing it today. It went a lot easier than I'd expected, really well put together tutorial, super easy to follow and understand.

I don't have felt, but I had a small pile of a heavier cotton twill fabric leftover from a vest, so I used that for both layers. My friend, the girl I've made this for, came out with the two hairclips that wound up as the accent bits on the hat. Super adorable, and I'm happy I could finally make her one of these hats as she's been wanting one for years.

shazni (author)2013-05-29

very nice indeed my dear i sound vintage? :-)

katvanlew (author)shazni2013-05-29

Thank you kindly!

groovymama (author)2013-05-27

I love this!

wobbler (author)2013-05-27

Can you believe that the Germans tried to stop the Allied forces advancing by using these? Even fully armed with a glue gun, I can't see them being much use.

Nice modern updated version though.

kcli (author)2013-05-27

Nice job! I had no idea how a hat was constructed and wondered how they kept hats secured. I also like the idea of wrapping felt around cardboard before covering with fabric. Great job!

elewis03 (author)2013-05-26

Hey that's me! I hope you win a contest with this, momma!

About This Instructable




Bio: I have been sewing and crafting for several years, my children are grown so now I have lots of time to be creative. I enjoy ... More »
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