Introduction: How to Make Bucket Hat

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Step by step instructions! With video tutorial in case you get stuck along the way.

Step 1: Video Instructions

Here is the video. Feel free to check it out if you get stuck.

Step 2: Supply List

-LINK to Pattern:

-LINK to Sweatbands:

-LINK to Sewing machine Singer 4423

-LINK to Polyester/Cotton Twill Fabric By The Yard Here:

-LINK to Bias tape folder attachment:

-LINK to Bias Tape:

-LINK to Grommet press + Eyelets:

-LINK to Fusible Interfacing:

Step 3: Pattern Assembly​

-Print out the pattern.

-Tape the pattern together following the key.

Step 4: Trace and Cut

-Trace the 3 panels onto the fabric.

-Place the top panel on the fold.

-Cut out. You should end up with 1 top, 2 sides, and 4 brims.

Step 5: Applying Interfacing

-Place fusible interfacing over the panels.

-Wrong side of the panels should be facing the adhesive side of the interfacing.

-Take iron and apply heat to the panels. Avoid hitting the table surface.

-We used paper to help with this process. The iron we used was to hot at the lowest setting and melted the interfacing. We solved this by adding a piece of paper between the iron and interfacing.

-Iron and let sit until the adhesive is try.

-Once the interfacing is ready cut our the panels.

Step 6: Sewing Brim

-Take the two brim panels with interfacing.

-Place the right sides together and sew both short edges.

-Flip the right side up and top stitch both seams.

Step 7: Sewing Brim

-Repeat step 7 for the 2 remaining panels.

Step 8: Sewing Brim Panels Together

-Take the 2 brim strips. Line up the side seams.

-Place the right sides together.

-Sew around the outside edge.

Step 9: Trim Edge

-Trim the remaining fabric.

-This will help clean straight edges when flipping the right sides out.

Step 10: Brim Stitching

-After flipping the right side out. Start stitching from the out side edge.

-Complete full loops around the brim and connect each brim stitch.

-Repeat this process until you reach the center of the brim.

Step 11: Sewing Side Panels

-Take the side panels.

-Place right sides together and sew both short edges.

-Trim the remaining fabric from seam.

Step 12: Twin Needle/Bias Tape Setup

-Place the twin needle into the domestic machine.

-Switch machine to zigzag stitch with 0 width.

-Add folder on to the machine. We used tape because our folder is designed for a industrial sewing machine.

-We show two different folders. They both make the same fold and will have to be taped onto a domestic machine. The yellow one is linked in the list of supplies and the industrial one is available at

-Thread the machine with two spools of thread and you are good to go! Thread both spools on the same exact path.

(TIP: Use the same color thread as the fabric. This is will help cover up imperfections.)

(TIP: It is easy to cut your own bias tape. Determine the required width of the folder you are using. Place fabric on place surface and cut diagonally to the fold.)

(TIP: Use a rotary blade and mat for best results.)

Step 13: Top Stitch/Bias Tape Side Panel

-Place the seam in the middle of the twin needle and sew all the way through.

-Do this for both seams on the side panels.

Step 14: Sewing Top Panel to Side Panels

-Mark the middle of the top and side panels with chalk.

-Line up the chalk marks with right sides together.

-Sew around the inner edge.

-Trim the remaining fabric from edge.

Step 15: Top Stitch/Bias Tape Seam

-Take the upper seam and top stitch just like in step 13.

Step 16: Attaching Brim to Top

-Line up the side seams of the side panels and brim panels.

-Place the right sides together.

-Sew around the bottom edge in a full loop.

Step 17: Attaching the Sweatband

-We made a guide out of heavy stock paper. Make sure it fits the sweatband nice and snug. This will keep the sweatband from moving around while sewing.

-Tape the guide on the machine.

-Sew on the edge of the lower crown.

-This process will attach the sweatband and also provide a top stitch.

-Leave about a inch of extra sweatband.

(TIP: Use a zipper/narrow presser foot and start sewing around the bottom attaching the sweatband. Keep as close to the edge of the sweatband as possible.)

(TIP: You can also make your own sweatbands by folding fabric in half or you can buy premade professional ones at We use the premade sweatband because they are cut on the bias. This helps them curve around your head with out bunching up.)

Step 18: Finishing Sweatband

-Roll the remaining sweatband over and top stitch.

Step 19: Adding Vents

-We are using eyelets for vents.

-Mark and cut one holes in panels on each side of the seam.

-Place the eyelets in the holes and use grommet press to secure the eyelets into position. If you do not have a press. Pliers work just as good and they are available at any fabric/hobby store.

(TIP: The pattern comes with hole positions. Remember to mark these when you are tracing the pattern.)

(TIP: For even spacing. Use a seam guide and measure from the cover button. This will help you keep the same spacing all the way around the cap.)

Step 20: Cap Is Complete​!

Thank you so much for reading our instructable! If you get stuck be sure to peek at the video for help! We will be adding more instructables in the future!