Here's an inexpensive way to make a pattern for a hat. I found a cute yellow striped hat at the thrift shop, but wanted to use it to make a pattern. I found a shirt at the thrift shop in a pretty blue floral print that I thought would be perfect for a feminine cap.
Step 1: Supplies
You will need an old hat, mine was the "Newsboy" type. Sewing machine, scissors, thread, denim scrap, stright pins, iron, measuring tape.Freezer paper or newspaper for the pattern and seam ripper. Elastic is optional. For the brim of the hat I used a scrap of denim with, what I like to call "Bacon paper". The thin, plastic sheet that bacon is placed on inside the packaging. It will help hold the shape of the brim and yet its thin enough for the sewing machine needle to go through. You can purchase heavy weight interfacing if you like.
Step 2: Cut Up Old Shirt
Cut up the shirt at the seams and iron pieces.
Step 3: Deconstruct Hat
Cut the crown section of the hat away from the hat band. Cut the brim off the hat band. With the seam ripper, separate the sections of the crown.
Step 4: Trace Hat Sections
Iron 1 or 2 sections of the crown of the hat. Since I cut the piece away from the hat band, I needed to add 1/2" seam allowance the the bottom. Trace around the section. I used freezer paper but newspaper works fine also. Place brim of hat on paper and trace around. Add 1/4" around front edge for seam allowance.
Step 5: Cut Out Crown of Hat
Cut 8 of the crown section. If you are making the hat out of striped fabric, make sure all the stripes are going in the same direction.
Step 6: Sew Hat Pieces Together
Pin 2 sections right sides together. Stitch down one side with 1/4" seam allowance. Set aside and repeat with the other 6 sections. Press seams open. You will now have 4 sections. Pin and sew one to another at the sides. Do the same with the remaining 2. You should now have 2 sections of 4 pieces each. Match up the pionts where the top of the hat will be and pin. Stitch these 2 sections together, creating the crown of the hat. Press seams open. Top stitch 1/8" on each side of seams.
Step 7: Cut Out Lining
Cut 8 pieces out of lining, or in this case, a light colored shirt.
Step 8: Sew Lining Together
Sew in the same exact manner as the crown of the hat. Place lining inside of crown section, Pin in place. Sew around 1/4" from the edge.
Step 9: Constructing Brim
Cut 2 pieces of the brim of the hat pattern. Pin these right sides together and sew around front edge with 1/4" seam allowance. Cut out the interfacing or plastic and denim combination, minus the seam allowance at the front of the brim. Place inside of brim and pin. Top stitch around entire brim 1/2" from edge. Clip curves up to, but not through, the stitching. Fold in half and place a pin at the center of the brim.
Step 10: Cutting Out Hat Band
Cut a piece of denim 1" x 25" for the interfacing of the hat band. Cut 2 pieces 2" x 25" for the inside and outside of the hat band.
Step 11: Pinning Hat Band
The front of the crown of the hat will be in the center of one of the sections between 2 of the seams. Fold one of the fabric hat bands in half and locate the middle. Pin this to the front center of the crown section, right sides together. Pin the other fabric hat band to the inside of hat, wrong side out. Pin the back seams of the hatband together. Repeat with the hat band lining. Check to make sure it fits around the crown well. Sew the back seams of the hat band and repeat with the hat band lining. Stitch around entire edge of hat with 1/2" seam allowance. Fold hat band down and also hat band lining. Place denim strip inside the hat band. Cut off extra. Fold the hat band down and under enclosing the denim interfacing. Pin. Fold the hat band lining down and turn edge under 1/2", Locate the front of the hat by finding the back seam on the hat band and the front of the hat is the exact opposite of that point. Place a safety pin at the front center. Place the seam allowance of the brim of the hat in between the hat band and the hat band lining, matching center points.
Step 12: Sewing Hat Band
If you want to put a little elastic in the back, place a 3" piece inside the hat band, stitch one side down, pull so it stretches a bit and pin. Adjust as needed. Stitch around the hat band 1/4" from the edge.The total cost of this project was about $3.00, and I also have a pattern for a cap if I choose to make another.
Step 13: Pattern
These are the measurements for the pieces. The hat band is 2" x 25". Cut 2 of those.