Kids Nautical Sailor Hat

Set sail in style with this Kids Nautical Sailor Hat! A classic accessory for sailor costumes, dress-up, theater productions, and themed events.

Supply List

5/8 yard of 45” woven fabric for hat exterior
⅜ yard of 45” woven fabric for lining
1/2 yard of interfacing
Notions: Matching thread, ½ yard of 1” grosgrain ribbon, 1 yard of decorative ribbon, Dritz Eyelet Pliers, Dritz 1/4” Eyelets

Step 1: Print pattern on A4 printer paper and assemble pattern.

Lay out the pattern & cut fabric for hat crown, crown lining, hat brim, and brim interfacing

Step 2:

Stitch three crown sections together, ending at the top dot. Evenly trim the upper edges of the seam diagonally to reduce bulk at the top.
Stitch the remaining three crown sections together, trim the upper edges
Stitch the crown sections together, ending at the large dot, trim the upper edges
Press open all seams
Looking at the right side, topstitch crown along the stitch lines. Flip inside out and trim excess seam allowance, trimming close to the stitch line.

Step 3:

Prepare lining same as the crown, following steps 3-6. Trim all seams (top to bottom) before pressing open
Slip lining over crown, matching at the seams
Baste raw edges together

Step 4:

Trim away the seam allowance from around the interfacing and apply interfacing to wrong side of one of the brim pieces
Pin brims together, right sides together. Attach by sewing sides and outer edge together
Clip corners and trim seam allowance down to ⅜”
Press seams open and flip brim so that it’s right-side out, press around edges
Top stitch lines into brim, following along outer ridge of the brim. Ensure that topstitching lines are ⅝” apart, leave 1” from the raw edge clear.

Step 5:

Pin the brim to the crown, raw edge matching. Ensure that brim edges are aligned with the center back. Finish the edge by serging or any other type of zigzag finish

Step 6:

To create an inner-band, pin one edge of the grosgrain ribbon to over the finished edge of the hat. Turn in and overlap the raw edge of the grosgrain ribbon. Stitch ribbon down.

Step 7:

Flip hat so that the brim in cast down, press the seam between brim and crown to smooth it out.
Flip hat so that the stitching on the ribbon is now the bottom edge. Clip or pin in place. On the inside of the hat, stitch the ribbon along the previous stitching.