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.