Step 1: Materials & Pattern
Create the pattern using the dimensions shown on the grid. (The pattern turned out to be too big for the brim. Cut it down to 13 inches wide, then you can fit it from there. I included a metric conversion chart from my grid.)
Step 2: Mark the Pattern & Pin
You can see that the sweater was too small for the entire pattern; use part of the arm, then sew it to the top of the hat. (turn the arm inside-out before you start.)
Turn the material inside out, then draw a line around the pattern.
If you are using a non-stretch material, or one that has a tight weave, you should be able to cut and then sew.
Step 3: Sewing
Turn the arm inside out, cut into a tall triangle, then sew to the top of the hat.
Cut the brim off.
Turn the bulk of the hat right-side out, but leave the brim inside-out.
Sew the brim to the bottom of the hat. The wrong side of the hat should be facing the right side of the brim.
Step 5: Variations
For the blue hat, I used 2 sweaters and feather trim left over from the corsage project. The belt buckle middle section was covered by hand sewing on a piece of the white sweater. The ball on top was made by knotting up the feather trim and hand-sewing it on.
The Texas hat was made from the middle of the shirt. Batting, plus some stars were added to the top. The brim was made of felt.
Be creative, and watch for the soon to be displayed upcycled stockings!
I wanted to thank the following Instructables for inspiring my brain on this project.
Make a Child's Sleep Cap From an Old T-shirt: by shabbychef
Make Mittens From a Used Sweater: by gridworks1