How to Sew a Jester Hat

A jester's hat comes in many shapes and sizes. The most common shape is a cap that has three horns mounted to it. The ends of each horn are decorated with a pierced coin, bell, pompom or tassel. Some are intended to make noise while others simply create the look of the jester. Usually a jester's hat is made out of fabric scraps since the tradition of the jester is that he was a poor fool. The hat should have many colors and look festive.

Things You'll Need

• Old baseball cap (sewn type)
• Seam ripper
• Fabric (at least 3 colors)
• Permanent marker
• Pins
• Scissors
• Sewing machine
• 26-gauge stainless wire
• Wire cutters
• Polyester stuffing
• Needle and thread
• Beads, coins or bells

Instructions

1. Find baseball cap that has been sewn together in sections. Use a permanent marker to mark each section of the cap in order. Example: A, B, C, D. Take your seam ripper and open the seams on the cap until you have several small cap sections to use as a pattern.

2. Pin each pattern piece to a different color of fabric. Cut out your cap pattern with scissors. With face sides together, pin your seams being careful to attach each piece in order before removing your pattern pieces. Sew your seams. You may also want to sew a liner for your cap the same way.

3. Cut six pieces of fabric that are 6 by 18 inches. Stack your pieces. Measure 3 inches to the center of one short side (all pieces at once). Pin. Cut your fabric starting at the other end in either corner. Cut from the corner toward the pin. Then cut from the other corner toward the pin. You should end up with long, skinny 18-inch triangle pieces.

4. Place two triangle pieces right-sided together and seam them along the long sides. Alternate your fabric colors and patterns for a festive look. Sew two more pieces and then the final two pieces. You should end with three triangles. Corner and reverse the fabric.

5. Cut three pieces of 12-inch wire. Cut three pieces of 8-inch wire. Cut 12 pieces of 18-inch wire. Bend your 12-inch wire into a circle. Fit your circle into the end of one horn so that 1/2 inch of fabric extends beyond the wire. Twist the ends of your wire together to hold the circle size and shape. Repeat this for the other two pieces of 12-inch wire.

6. Make a circle of each of your 8-inch wires and twist the ends together. You should now have three large wire circles and three smaller wire circles. Take four of your 18-inch wires and twist one end together. Bend the twisted ends over. Spread out the four wires so they are roughly evenly spaced. Slide a smaller circle between the spaced wires about 8 inches from the twisted end. Wrap each of the 4 wires over the smaller circle to hold it in place.

7. Slide a larger circle between the space wires about 1/2 inch from ends of the wires. Twist the ends of the wires around the larger circle to hold it in place. You should be able to slide the wire horn shape up inside your fabric triangle so that the fabric overhangs the bigger circle by about 1/2 inch. Stuff your fabric horn with pillow stuffing and pin your horn to your cap. Repeat for all three horns. The wire inside each horn allows you to bend and shape the horns.

8. Put the cap on and check the placement of the horns in the mirror. Make any adjustments and, tucking the fabric under, sew each horn onto the cap. Add tassels, bells or pompoms on the ends to finish. Sew your liner or hem the bottom edge of the cap. Bend your horns for the shape you want.

Tips & Warnings

• Reduce the size of your horns if you are making a child's cap and consider adding ties to hold the hat in place.

References

• Whatever Is On My Mind Today: Jester Cap
• AMT Gard: How To Make a Court Jester Cap