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How to Make a One-Pattern-Piece Reversible Sunhat

cal patch, contributor

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You can make a shady hat like this, from start to finish!

Cal Patch

Plot out the length and the half-width of the hat on folded paper.

Cal Patch

Draw a line straight up for half the length of the hat.

Cal Patch

You can make a shady hat like this, from start to finish!

Photo: Cal Patch

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I'm a big fan of sunhats; 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.

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)
• Scissors
• A tape measure
• Remnants of two different light- to medium-weight woven fabrics

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.

Plot out the length and the half-width of the hat on folded paper.

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.

Draw a line straight up for half the length of the hat.

Then curve the line to meet the top point (at the fold) as shown.

Curve the top half of the hat.

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.

Plot out the brim, as long as you like.

Square a line out from the bottom point of the brim line, toward the fold.

Square the bottom of the brim to establish the lower edge.

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.

Square from the fold to meet the other line...

...and blend the two lines into a slight curve.

4. Add seam allowance. Measure out evenly 1/4 inch all around the pattern piece for seam allowance, and draw it in.

Add seam allowance and your pattern is complete!

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 http://hodgepodgefarm.blogspot.com/ and etsy shop http://www.hodgepodgefarm.etsy.com.

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Comments (14)

CalPatch writes: JennieC: yes! this is the reversible tulip hat. good eye!
Posted: 10:49 pm on July 28th

JennieC writes: Is this the same as the reversible tulip hat you're selling on Etsy? I really want to try this. Maybe I can get my teen to make a hat and quit baking her face. She will SO regret it some day.
Posted: 10:54 pm on July 20th

Flippincool writes: Thanks so much for a great tutorial! I've linked to this in a summer tutorials post on my blog, The Handmade Experiment. Check it out at http://emilyflippinmaruna.wordpress.com/2009/06/15/must-make-monday-its-summer-tutes/

Thanks and have a great summer!
Emily
Posted: 1:34 pm on June 15th

MrsMessy writes: Your tutorial came at the perfect time. I was looking for a red hat for my baby and was not happy with what I found in the stores. Your directions made this project a snap. Thanks so much! You can see the hat I made on my blog, here.
Posted: 10:20 pm on June 2nd

sewold writes: I haven't made this one yet but I like the shape. I've made other anti-sun hats and use old jeans denim a lot for projects like this. Cutting from different pairs or different parts of a pair gives you a lot of variation in color but it all blends well. I use old denim a lot (I've kept a stash) for hats and purses. Incorporating details like pockets makes it fun, too.
Posted: 9:06 am on June 2nd

cherylzone writes: I can't wait to make this....and can't wait to buy your book. I noticed the fence in the background of the photos....did you make it too?
Posted: 12:23 pm on May 31st

goddessmichellev writes: Love it! can't wait to try this! Thank you so much!
Posted: 3:41 pm on May 30th

SweetbriarStudio writes: What a great tutorial on a cute and, dare I day, practical hat! Thanks for making it easy.
Posted: 10:30 am on May 30th

CynRed writes: Living in the Southwest I'm always looking for comfortable hats. I can hardly wait to make this!
Posted: 10:00 am on May 30th

TheStylishStudent writes: A nice, quick design. I'm looking forward to purchasing your book.
Posted: 9:53 am on May 30th

subloke writes: I love this and can't wait to try it out when i get home!
Posted: 11:52 am on May 28th

mommaviv writes: I think I can do this! Can't wait to try.
Posted: 3:30 pm on May 27th

garnetnm writes: Good tutorial. Thanks. A few years ago I said no more pattern drafting. This may make me change my mind. :)
Posted: 9:35 pm on May 26th

LindaPermann writes: Very cool Cal! I'm looking forward to your book, and I'll probably whip up this hat in the meantime.
Posted: 12:45 pm on May 26th

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