Here Comes the Sun Hat {Free Pattern}

If you're not interested in my rambling story skip to Paragraph 4  :)......

Hats are a funny thing.  I love my kids in hats.  Especially boys.  Ezra melts my heart when he's wearing a hat.  I think Lila is still cute in hats.  And Madelyn has to wear hats because she's a fair-skinned chub of a child.  My mom thinks that my generation is overly dramatic about the way we cover our kids with hats and sunscreen. The thing is I never used to care.  I'm pretty naturally pale, {isn't that nice.  It comes naturally.... :)}  So when I was younger, I used to go tanning {mostly in the winter}.  I was part of the experimental tanning bed generation.   I never really thought of it as bad for me and I liked being tan because I felt like I looked healthy instead of yellowy pale.  I played outdoor sports in the spring, summer, and fall, so I was almost always tan.  And then all the research started coming out about ya know, skin cancer, and I told myself I'd go less.  And then I got married to Superman and he sort of hinted that he'd like me around to be the {pale} mother of his children instead of the tan dead lady.  So I haven't gone tanning in years.  And I'm cool with that.

So fast forward to mom-hood.  I'm pretty strict about sun-screening and hatting my minions.  It seems pretty hypocritical, I know.  I figure when my kids get older, they can rebel and do what they want with their skin.  But while they're mine, they'll be sun screened when we go outdoors for long periods of time.  And my semi-bald babies will wear hats.

Anyway, I'm pretty exited about this.  A long time ago in a far away galaxy...when Lila La La Loopsy was a baby, I bought her a polka dot sun hat.  I loved it on her.  And then one day, it was gone.  Gone.  I couldn't find the little beast anywhere.  I wanted to make one ever since.  {It's only taken me this long to figure it out in my head!}  Because darn it, little baby hats are pretty pricey and I know they go on sale, but this little pattern and tutorial will keep little baby heads covered for next to nothing.  Chu-ching!
Some things to note about the "pattern."  I'm a newbie to any type of pattern making, so I realize this draft is rough.  I've tested it on a few hats, but as far as printing goes, I'd just keep settings to your "standard" or possible 100% scaled not shrink to fit and you should get the same dimensions.  I've made this to fit a 6-24 month old depending on the head size.  Madelyns head {is seriously adorable} but it's a little bigger than normal, so I made the hat bigger for her to grow into.  Her head is about 17.5 inches.
Also, if you want the brim not to flop, you'll want to attach some fusible interfacing and you'll need to make sure it's stiff.  And don't forget that this pattern is for personal use only!  Please don't redistribute or sell!  Thanks!

What you'll need:
  • This two page pattern
  • 1/2 of a yard {between 1/4 and 1/2 would do} of main fabric
  • 1/4 of a yard of lining
  • Coordinating thread
  • Velcro {only about 1/4-1/2''}
  • *Optional* Stiff fusible interfacing {if you don't want the brim to flop}

All seam allowances are 1/4'' unless otherwise noted.  

Step One: Print, cut and cut some more:

First print out the pieces, and cut out the outlines according to instructions.  You should have something like this:

Minus the full circle.  You'll just have a half circle.

And then cut your material according to instructions. In the end you'll have:
Now the rest of this is easiest if you assemble each thing and attach it all together at the end.

Step 2: Assemble straps

Fold and press rights sides together.
 Now sew down the open side leaving the ends open.
Safety pin one end.

And pull your safety pin through so that your right side is showing.

Now fold in the bottom of the strap so that you can't see the raw edges.  And top stitch.  {One end of the strap will be tucked inside the had so you can leave it raw}

Now add one piece of velcro.

And do the same with the other strap and set both straps aside.
Step Three:  Assemble Top

Attach the top pieces to your main fabric by putting right sides together and sewing up one side.
Now add another piece {again r.s.t.} and do the same until all four are sewn on.
Now just attach the two ends {r.s.t.} and sew.
Do the same with your lining.  Now you'll have two top hat forms.
Step 4: Attach everything
Optional: If you have fusible interfacing, this is where you'd add it.  Iron it to the wrong side of either one of the circles.  

Attach the circle brim to the hat top.
 Pin right sides together
and sew around the main fabric.
Now attach your top hat lining in the same way, only be sure to pin your straps in {about 1/2'' inside the lining} on either side.  I put mine about halfway on each side.  Make sure one strap's velcro is facing inward and the other straps velcro is facing outward.  {So that they'll attach correctly when it's done.}

Sew straps in by sewing around like you did on the first top and circle.

Attach the lining side and the main hat by placing right sides together and pinning.  Ensure that you tuck the straps inside toward the middle so you don't accidentally sew them in.
Sew both circles together {r.s.t.} and leave a 2'' hole.

Step 5: Finish Work

Turn the newly attached pieces right side out by bringing the right side through the hole.
Fold the raw edges towards the inside {or wrong side} of the hole and press.
Sew the hole closed and continue to top stitch around the entire circle.
Top stitch above the seam that attaches the top and brim of the hat. {Be sure to move the straps downward while you stitch.}
And you're done!

Say what?  You just made a hat!
Put it on a squishy baby head and go enjoy some sunshine!


  1. Okay, that is nothing short of amazing! I hope you won't judge me for not SunscreenIng my kids as well as I should… But perhaps if their Aunt Beth made Them a cute polkadot hat… :-) you know their mother Doesn't have the skills necessary…

  2. Anonymous5/15/2014

    I just stumbled upon this and you've written it in a well detailed way, I love all the pictures, it makes it look like I can do it so I will be giving it a try later! Thanks!! :)

  3. Thanks so much for sharing this pattern and tutorial. One thing: I had to print at 110% to get the 1" test square to equal 1 inch (measured to outside edge of outline). Maybe this is an issue unique to my set up (macbook + brother printer), but just wanted to let you know. :)

    1. Thank you so much for letting me know! I really appreciate it, since I wasn't able to really "test" this pattern out on other printers! Thanks again!

  4. Thank you very much for this pattern. Sorry for my english but i couldnt understand if the patterns have already the edge to sew (i really dont know if i said it right, I mean the space por the sewing) I love this projetc!

  5. Just tried this and it came out adorable! Thank you so much. It was really well explained.

  6. Wow, thanks for this pattern! It's just what I was looking for to make nice summer present. :) Say, is the drawn pattern one-size-only, or is there some way to make it smaller or bigger? I used my poor maths skills to make the pattern to fit my needs, but maybe there is a better way of doing it... :D

  7. OMG! My new granddaughter's head is only 13inches around. I guess I could just make bigger seams. Any other suggestions for a tiny head?

  8. I cant see a link for this?

  9. where is the pattern??

  10. I don't know why, even though I printed it (had to print it at 107% to get the 1" square) the brim and the sewn top part do not match, the brim is way too big and I have like 2 inches slack :( I'll have to modify the pattern to make it work.

    1. I also had the same problem with the same 2" slack. I am also making mine reversible.

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  13. i must be crazy but i do not see the pattern anyware!

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  15. Nice post..

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