How to Make a One-Piece Reversible Sun Hatcomments (34) June 1st, 2016
I'm a big fan of sun hats; they keep my face from becoming one giant freckle. I like to make them in all different fabrics so there's one for every occasion, and they're even better if they're reversible! This is a very simple style that you can whip up the pattern for in a few minutes, and it works for any head size from baby to adult.
Supplies you'll need:
- A piece of paper, any kind will do (8-1/2 x 11 inches is plenty big enough; I used a scrap)
- A pencil
- A ruler (ideally one you can use for squaring)
- A tape measure
- Remnants of two different light- to medium-weight woven fabrics
Make the Pattern
1. Take some measurements. Measure the circumference of your head at its widest; just above the ears should work. Jot this number down, then divide it by 6 (it's a six-panel hat). Then divide that number in half because we're going to make this pattern on a fold, so we'll only draw half of it. This is the number you'll need. My head measures 22 inches around, a sixth of that is 3.66 inches, and half of that is 1.83, or 1-7/8 inches. (You could just divide the circumference by 12, but I want you to understand what you're doing and why.) Then measure the height, from the top of your head to the middle of your ear. Mine is 7 inches. Jot this down, too.
2. Let's draft! Fold your paper in half lengthwise, and orient it so the fold is at left, as shown. Near the top of the paper, make a mark on the fold to indicate the topmost point of the hat. Measure down from this point the height you measured from your head, and mark. From this point, square a line out from the fold. Along this line, measure out your (half of) one-sixth head circumference measurement, and mark.
Now find the halfway point between the top of the hat and the bottom. Draw a line straight up from the head circumference point to here.
Then curve the line to meet the top point (at the fold) as shown.
3. Add the brim. Decide how long you want the brim of your hat; something like 2 to 3 inches is a good starting point. Continue the straight line down for as long as you want the brim. Then measure out to the right, from the bottom point, to add some flare to the brim. I'd suggest about 3/4 inch. Angle the ruler from this point up to your original circumference point, and draw the brim line again along this angle.
Square a line out from the bottom point of the brim line, toward the fold.
Square a line out from the fold to meet the bottom edge of the brim, and blend the point into a smooth curve as shown.
4. Add seam allowance. Measure out evenly 1/4 inch all around the pattern piece for seam allowance, and draw it in.
That's it! You've made the pattern. Cut out the piece while still folded and you'll have a perfectly symmetrical pattern piece. Label it "Cut 6" and grab your fabric!
5. Cut the pieces. Cut six of the pattern piece from each of your two fabrics (remember, it's reversible: two hats in one!).
6. Sew them together. With right sides facing, sew two pieces of the same fabric together along a vertical seam. Add a third, and continue until all six are seamed together, then sew the final seam where the sixth piece joins the first. Repeat with the other fabric. Press seams open. Place the two hats together, one inside the other and with right sides facing. Sew along the brim edge, leaving a 3-inch to 4-inch hole to turn it right side out. Turn, press the brim edge, and edgestitch around, closing the hole.
Once you've done it, play around with different brim sizes and angles to see what kinds of shapes you get. Try cutting the pieces from assorted fabrics or alternating two or three colors. Add trims or appliqués, or embroidery...the sky's the limit, as long as the sun is off of your face!
If you thought making this pattern was fun, check out my upcoming book, Design-It-Yourself Clothes: Patternmaking Simplified, due out in September 2009 from Potter Craft! You can also keep up with me at my blog and etsy shop.
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