How to Make a Felt Hat

These simple tools are needed to create this felt hat: a measuring tape or ruler, pins, scissors and a needle. Materials used to make the hat are the torso portion of a felted wool sweater, wool yarn and two large buttons.

Please see the last slide for an itemized list of materials.

Choose a felted wool sweater with a bottom edge wider than its waist. Note that the bottom edge becomes the brim of the hat so beware of worn edges.

In order to more easily work with the torso portion of the sweater, turn the sweater inside out and remove the sleeves by cutting inside the armhole seam.

Measure head size and adjust instructions as needed. The instructions given are for the most common women's head size (circumference 22 inches). To adjust the size, increase or decrease measurements proportionally in reference to head circumference.

Turn the torso section right-side out. Match the side seams in the middle and pin them together. Measure 9 1/2 inches from the bottom edge of the sweater and pin horizontally through both layers from one side to the other.

Cut the felt horizontally along the pins and vertically at the right fold line.

Rotate the felt about ninety degrees so the remaining fold is at the top. This fold will be the top center of the hat. Starting at the fold, measure 11 inches down on the right side, 12 1/2 inches down from the midpoint, and 14 inches down from the left side. Mark each point with a pin.

Cut through both layers of fabric from the right to the left, creating the curved lower neck edge of the hat. Use the pins as a guide.

Thread the needle with about 30 inches of yarn, double it, and tie a single knot using both ends.

Using a whip stitch, join the two layers of fabric on the right side of the fold starting at the bottom and sewing upward. This will create the center back hat seam. Stop the seam about two inches from the fold, leaving a 2-inch hole. Knot the yarn on the inside.

From the remaining portions of the sweater, cut approximately 21 strips of felt 1/2 inch wide each; seven strips 7 inches long, seven strips about 5 inches long, and seven strips about 3 inches long.

Thread the needle with about 24 inches of doubled yarn, knotting both strands together. Insert the needle 1/2 inch from the end of each strip, starting with the longest, and pull them tight to the knot. Finish with the shortest strip and tie another knot to secure.

To create the tassel, roll or fold the strips together, sewing in place as needed. Insert the tassel into the 2-inch opening.

With the tassel perpendicular to the back seam, sew through the hat and tassel several times, securing the tassel in place. Finish with yarn to the inside and knot securely.

Make ties by cutting two, 12-inch felt strips (5/8 inch wide each) from the remaining portion of the sweater.

Try the hat on and decide where to place the ties. The ties are decorative as well as functional and should be placed where they comfortably hold the hat on the head. Generally the placement is even with the bottom edge of the back center neckline (with the hat flattened) and about 3 inches inside the front edge of the hat.

Starting from the inside, sew the ties and buttons to each side of the hat. Knot the yarn on the inside.

Measure a 10-inch line, two inches from, and parallel to, the bottom edge of the hat with the back seam in the center. With 24 inches of yarn (doubled), sew a simple straight stitch (about 1/2-inch stitches) along the line.

Pull the thread and gather the fabric of the neckline to fit. The total seam length should be about 5 inches. Knot the thread securely on the inside. Tie the ties together under the chin for warmth or leave ties loose for a relaxed look.