Bucket Hat

Bucket Hat

Little fact about me, I love a hat! Mainly because my hair has a life of its own, so on bad hair days, I can just hide it under a hat when I’m out and about. One of my favourite hat styles to wear is a bucket hat, they are cute and can be suitable for any season depending on the fabric. The best thing about them is that they are so simple to make yourself! And even better you can make them by upcycling old clothes!

Upcycling is a huge part of my life. We live in such a throwaway society and it makes me incredibly sad. Before I bin anything, I always try to think if there’s anything else I could reuse the item for. From empty candle jars (check out the Fairy Lights jar tutorial) to wine bottles to old Christmas decorations. There’s not much that can’t be repurposed.

There are loads of free patterns out there you can use to make your bucket hat, or you can get my free pattern that I use in this tutorial for free by joining our newsletter! Don’t worry, I won’t be spamming you with emails, you will only get the occasional one to alert of any new tutorials and freebies so you don’t miss out.

What you will need

  • Pattern
  • Fabric
  • Chalk
  • Scissors or rotary cutter
  • Pins (or clips)
  • Sewing machine
  • Thread
  • Iron

For this this hat I used a pair of old denim jeans (size ten wide leg) that no longer fit, you can use almost any fabric, (my preference is heavy fabric such as denim or corduroy) however I would avoid anything stretchy.

Start off by printing out your pattern and cutting around it. The pattern is designed to be printed on A4 paper so can easily be printed at home.

If using an old pair of jeans, cut along the length of the leg so you are only working with one layer. You can either pin the pattern in pace and cut, or use chalk to mark your pattern and then cut. I tend to do this as I like to reuse the pattern which can get damaged with pins.

You will need

1 x circle for the top

4 x pieces for the brim

2 x pieces for the headband

On the headband and brim pattern you will see “on the fold” printed on one edge. What is meant by this, is that the fabric needs to be folded over at that edge so when cut you will have a piece that is double the length of the printed pattern. I recommend pinning the 2 layers of fabric together before cutting to ensure it does not move around when cutting.

Once all the pieces are cut you will end up with 7 pieces in total.

Start your hat by working on the headband. Place the two pieces together right sides facing each other, pin the two short sides and sew together.

Take your circle piece, fold in half and make little cuts on the edges to mark the centre (or you can mark them with chalk).

Time to attach your headband to the top piece. Open the headband piece and (right sides facing each other) pin the stitched down side to the previously marked side of the circle. Do the same for the other side. You will have something that looks like this.

Working with one side at the time, start pinning the remaining fabric together until you have a complete circle. You might need to manipulate the fabric slightly up or down to make it fit.

Slowly sew the two pieces together. When completed you will have something that looks a bit like a chef’s hat. Put this aside and start working on the brim. This is my favourite part and so satisfying for my ocd brain!

As you did for the headband, place 2 pieces together, right sides facing each other. But this time instead of the short sides, pin the longest sides together and saw.  (Leave the sides and bottom open). Repeat for the remaining 2 pieces.

Once this is done, you need to join the sides. Open the brim, right sides facing each other, pin the 2 short sides together and sew.

Turn the right way around and you now have a full brim. At this point I like to iron this section.

You will notice that the brim is very floppy, so we need to add some strength to it. We do this by making rows of straight stiches (The satisfying part!!). For this you can use the same colour thread of your fabric, or you can use a contrasting colour to make it pop, you can even use a different colour for every line!

With your sewing machine start stitching a straight line all along the closed edge. I use the markings on my machine to make sure my lines are straight but if you don’t feel confident you can mark it with chalk. Once the first row of stitching is done you want to carry on making more rows until you get to approx. ½ inch away from the inner edge. 

Time to put your hat together! As both sides of your brim should be the same it doesn’t matter which side you choose (unless it’s a patterned fabric, then pick whichever you like best and make sure this side the top of the hat. I find it easier to place the top part of the hat inside the brim when doing this.

As you have done previously, start by matching the middle (stitched) sides and pin together. Again, work on one side at the time by pinning all the fabric together until you have pinned the whole circle. Sew it together.

Your hat is almost complete. The last thing I like to do is to “clean” the edges to prevent it from fraying. You can do this with an overlocker or the zigzag function on your sewing machine.

And there you go, you now have your own upcycled bucket hat!

I absolutely love seeing what you’ve created, so if you do make this hat (or any other items from my website) don’t forget to tag me over on my social media pages 

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