Scalloped Sun Hat Sewing Tutorial

Get the pattern here. See the video here.

This pattern is for sizes micro to 12 month. Don’t be fooled by the Styrofoam heat, I don’t have a baby head model 🙂 The hat pictured below is a size 12 month.

The Basics:

You will need as little as a fat quarter for the smallest size, and as much as 1/2 yard for the larger size. For this tutorial, I used a different color for the lining, but that is not necessary. Other materials needed include some kind of ribbon or strap for the chin closure and a ribbon bow, or other feature, for the back of hat decoration. Use your imagination!

Sew the smaller sizes with a 1/4″ seam allowance and the larger sizes with 5/8″ seam allowance. Don’t worry… this pattern is forgiving, so don’t worry too much about the seam allowance. Just use whatever is most comfortable for you and your machine.

This pattern also requires the use of a hand needle for the turn out portion and to secure the decoration.

Cut the pattern along the black lines. Use the table on the first page to guide you. Choose a size and only print the page needed for the project to save paper and ink.

Sew the scalloped brim:

With right sides facing, sew the scalloped edge of the brim.

Slash the seam allowance, especially in the pointed areas. Careful not to cut the stitching.

Turn the brim right side out and press well. Set aside.

The Crown:

Sew 2 pieces of the crown together at a time, with right sides together. There will be two pairs of the outside materials and two pairs of the lining.

Open the pair of crown pieces and add a third. This will result in four trios of crown pieces.

There will be a total of four trios of crown pieces.

Place the trios of crown pieces together with right sides facing and sew them together.

Leave a small space on the lining for turning, as shown in the picture below.

Find the middle of the front of the brim by folding in half and mark it with a pin.

Find the middle of a crown piece on the outer fabric and pin the brim into place. The end of the brim will almost meet in the center of a crown piece, as well. Pin the brim into place and readjust as necessary to make it even before continuing.

Straps (Optional)

Pin the straps to the seams on either side of the crown. They should be the seams that join the trio pieces together.

Pin the straps to the side of the hat with the brim attached as shown in the pictures below.

Place the outer crown inside the lining crown, right sides facing, and pin all layers together. Sew around the brim of the hat.

Use the small space in the lining to turn the hat right side out. Use an iron to press down the seams at the crown.

Hand sew the opening in the lining.

Attach a decoration to the back of the brim. In this case, I am using a wide grosgrain ribbon. It was handsewn in place.

That’s it! Happy Sewing! Keep scrolling for the video.