Bucket Hat Tutorial

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The bucket hat, traditionally worn by fisherman and farmers, has an all-around brim which protects your eyes and face from the sun’s rays. This stylish hat can be worn many ways by folding the brim on different sides. It is reversible, easy to make, and can be fashioned from many fabrics.

Things You'll Need

  • 1/2 yard of two fabrics
  • Iron on interfacing
  • Scissors
  • Pins
  • Iron and ironing board
  • Sewing machine
  • Template (See Resources)
This hat is reversible.
This hat is reversible. (Image: Debbie Williams)

How to Make a Bucket Hat

Step 1

Choose lighter weight fabrics for summer and wools, corduroys, flannel and other heavy fabrics for the cooler weather in the fall and winter. Please see the last slide for an itemized list of tools and materials.

Things you'll need.
Things you'll need. (Image: Debbie Williams)

Step 2

Print and cut out the template (see Resources on the last slide). Cut one hat top, one band, and one brim from each fabric. Be sure to cut the bands and brims on the fold as indicated on the template.

Cut the pieces.
Cut the pieces. (Image: Debbie Williams)

Step 3

Cut one hat top, one band, and one brim from iron-on interfacing, using the cutting lines indicated for interfacing. Iron the interfacing onto one set of fabric pieces.

Press the interface onto one set of pieces.
Press the interface onto one set of pieces. (Image: Debbie Williams)

Step 4

Starting with the interfaced pieces, stitch the band into a circle, using a 5/8-inch seam allowance.

Sew the band into a circle.
Sew the band into a circle. (Image: Debbie Williams)

Step 5

Clip the inner curve of the band about every inch. Make each cut about 3/8 inch deep, and be careful not to cut too close to the 5/8 inch seam line.

Clip the curves.
Clip the curves. (Image: Debbie Williams)

Step 6

Fold the hat top in half and mark the center on each side. Mark the middle point on the band piece. Match one center mark on the hat top with the mark on the band and pin in place; match the other mark on the hat top with the mark on the band and pin in place. Matching raw edges, pin the band to the hat top all the way around.

Pin the band to the top.
Pin the band to the top. (Image: Debbie Williams)

Step 7

Stitch the band to the hat top, avoiding puckers or pleats. Do not sew over the pins -- remove them ahead of your stitching as you work your way around the band.

Sew in the top.
Sew in the top. (Image: Debbie Williams)

Step 8

Press the seam toward the band and turn the assembly right side out. Topstitch close to the seam line on the band side.

Top-stitch close to the edge.
Top-stitch close to the edge. (Image: Debbie Williams)

Step 9

Pin the brim to the lower edge of the band as described in steps 5 and 6. Stitch this seam in place. Press the seam toward the band and topstitch on the band side.

Add the brim to the hat.
Add the brim to the hat. (Image: Debbie Williams)

Step 10

Repeat steps 4 through 9, using the second fabric. Pin the assembled pieces together, right sides together and the center seams matched.

Pin the hats together.
Pin the hats together. (Image: Debbie Williams)

Step 11

Stitch around the lower edge of the brim, leaving a 3-inch opening to turn the hat. Turn the hat rightside out through the opening. Press in the seams at the opening and top-stitch close to the edge all around the brim edge, closing the opening. Topstitch the seam between the hat band and the brim.

Finishing up the hat.
Finishing up the hat. (Image: Debbie Williams)

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