Introduction: How to Make Toddler 5 Panel

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Step by step instructions! With video tutorial incase 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: List of Supplies

Here is a list of supplies we highly recommend. (TIP: Using the right grade supplies will drastically improve the quality of your fitted cap.)

-LINK to Pattern:


-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:

Step 3: Cutting Pattern

-If you are using the ProperFit pattern be sure to cut on the outside of the black line.

Step 4: Trace and Cut

-Trace the 3 panels onto the fabric.

-Cut out. You should end up with 1 front, 2 side, and 2 top panels.

(TIP: Be sure to mark the top of the front panel.)

Step 5: Top Panels

-Take the top two panels.

-Place the right sides together.

-Sew across the middle top edge with .25 inch seam allowance.

(TIP: Make sure you sew the correct edge. The shorter side is the correct edge.)

Step 6: Setting Up Bias Tape

-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 7: Top Stitch Top Panels

-With the folder into position and the bias tape cut.

-Feed the bias tape trough the folder.

-Line up the seam in the center of the twin needle and sew.

(TIP: Using this method will cover up the inside raw edge and leave a professional twin top stitch on the outside.)

Step 8: Interfacing Front Panel

-Place the wrong side of the front panel down on the adhesive side.

-Only apply the interfacing to the front panel.

-Use iron to apply the interfacing.

-Cut off remaining interfacing around the panel.

(TIP: Use a sheet of paper to help iron on the interfacing. This will keep your iron and work station clean.)

(TIP: We are using a heavy weight interfacing designed specifically for cap making. This interfacing helps keep the front panel structured. Use the heaviest weight interfacing for most professional results.)

Step 9: Sew Front and Top Panels

-Take the front panel and top panels.

-Place right sides together and sew.

-Trim the seam allowance.

(TIP: Make sure you are sewing the top edge of the frond panel to the front edge of the top panels. The top edge of the front panel is curved. We recommend marking this edge when you are tracing it onto the fabric.)

Step 10: Top Stitch Front Seam

-Just like in the previous top stitching step.

-Place the front seam in the center of the twin needle and begin to sew.

Step 11: Attaching Side Panels

-Place the right sides together and begin to sew around the curve.

(TIP: Do not put the fabric as you are sewing. Let the fabric fall into place as you sew around the curve.)

-Make sure you are sewing the curved edge to the outer edge of the top panel.

-Trim the seam allowance.

-Repeat this process for both side panels.

Step 12: Top Stich Curves

-Just like in the previous top stitch steps.

-Set the machine up.

-Begin to work around the curve. Make sure the seam is in the middle of the twin needle. GO slow so. The curve is tricky to stitch around.

-Do not get Discouraged if it does not turn out perfect on your first attempt. It will take a few tries to get this step down.

Step 13: Making Bias Tape

-Using the bias tape kit. Pick the side you would like to use.

-Cut the fabric for the size folder.

-Feed the fabric through the folder and begin to pull the folder with iron trailing.

-You will end up with a double fold tape ready to cover up the back arch opening.

Step 14: Attaching the Bias Tape

-Take the crown and the bias tape.

-The bias tape kit comes with a presser foot guide. You can use this to help attach the bias tape onto the raw edge.

-We attached it without the presser foot. Fold the tape in half and place it over the raw edge. Go slow and be sure you are sewing all layers.

Step 15: Adding Size Strip

-Take the size strip and sew it on the inside of the crown along the bottom.

-Sew directly in the center of the size strip.

(TIP: The size strip helps give support and structure to the bottom edge. It is key component for making a quality cap.)

(TIP: If you are on a budget. Use heavy weight paper. I recommend not skipping this step.)

Step 16: Making Brim Sleeve

-Place the brim you are using onto the fabric.

-Trace the front curve.

(TIP: Trace past the end of the brim. This will give you extra room to work the brim into position.)

-Stitch directly on the trace line.

(TIP: The closer to the inside you stitch, the tighter the fabric will set on the brim.)

-Cut about .25 inches from the seam around the outside edge.

(TIP: Leaving .25 inches will help the brim set on one side of the sleeve. This will make the front edge of the brim seam look straight.)

-Flip sleeve right side out and insert the brim.

(TIP: Slide the brim on one half of he seam allowance. The seam allowance will act as a guide.)

Step 17: Locking Brim Into Position

-Make sure the brim is in the sleeve nice and snug.

-Stitch along the back curve of the brim.

(TIP: Use zipper or narrow presser foot to sew along the back edge of the brim. This will help get your stitch as close as possible to the edge of the brim.)

(TIP: Pull the back half of the fabric away from the needle as you sew. This will help keep the fabric tight on the brim.)

Step 18: Brim Stitching

-When the brim is sew into the sleeve.

-Stitch on top of the brim near the outside edge. This will secure the fabric even more.

-We are using a brim guide. This guide is build for a industrial sewing machine so we had to lock it down with tape. The guide helps with getting parallel stitches around the brim.

-Cut back access fabric about .5 inches from the brim.

(TIP: For perfect stitch lines around the brim you should consider using a guide or block. Something you can use to keep the brim moving in one motion around the curve.)

(TIP: Use the same color thread as fabric. This will help make the stitch lines look straighter and uniform.)

Step 19: Attaching Brim to Crown

-Mark the center of the brim. Match it with the center front seam.

-Place right sides together and sew from the center towards the outside edges. Repeat for the other half of brim.

(TIP: By starting in the center. This will help keep the brim positioned in the center of the crown as you sew.)

(TIP: Use a zipper/narrow presser foot to help get as close as possible to the edge of the brim.)

Step 20: 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.

-Roll the edge of the crown over so the wrong side of the sweatband is touching the right side of the crown. Begin to sew.

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

-Leave about a inch of extra sweatband.

(TIP: Roll the size strip over. This is the perfect amount for attaching the sweatband. Use the size strip as a guide.)

(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 21: Adding Back Closure

-Take your desired closure. offers a wide variety of closures to take your cap to the next level.

-Fold the sweatband into the cap. Sandwich the plastic snap in between the sweatband and crown.

-Stitch into place and repeat this process for the other half.

Step 22: Adding Air Vents

-We are using eyelets for vents.

-Mark and cut two holes on side of middle of the side panel.

-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.

Step 23: 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!