By Jo @SewlyJo
Beat the heat in style with this breezy, customizable sun hat that’s perfect for summer strolls, beach days, or garden lounging. Whether you're a beginner or seasoned stitcher, this step-by-step guide will walk you through pattern drafting and construction for your very own floppy sun hat—with compass precision!
Video Tutorial Below👇What You'll Need
| Tool/Fabric | Details |
|---|---|
| Compass & measuring tape | For accurate radius and circumference |
| Pattern paper (or large scrap paper) | To draft your pattern |
| Fabric – lightweight & breathable | Cotton, linen, rayon—great for flop & comfort |
| Pencil, scissors, pins | Basic sewing tools |
| Sewing machine | With a standard presser foot |
| Optional: interfacing | For added brim structure |
Step 1: Measure & Calculate
Start with your head circumference. Mine is 23.5 inches.
- Radius for crown and brim base = Circumference ÷ 2π (6.28) ≈ 3.75 inches
- Add ¼ inch seam allowance = Final pattern radius: 4 inches
Step 2: Draft Your Pattern
🔹 Crown (Top of Hat)
- Use compass to draw a 4-inch radius circle
- This includes seam allowance
🔸 Side Band (Middle Section)
- Height: 5 inches (includes ¼" seam allowances top and bottom)
- Length: 24 inches + ½" seam allowance for joining = 24.5 inches
- Draw a rectangle: 24.5" × 5"
🔻 Brim
- Inner circle radius: 4 inches
- Brim width: 3.5 inches average
- Add ¼" seam allowance → Outer radius: 7.5 inches
- Draw a donut-shaped ring:
- Outer circle: 7.5" radius
- Inner circle: 4" radius
💡 Tip: Create a brim lining or add interfacing if you want less floppiness and more shape.
Step 3: Cut Your Fabric
- Cut 1 crown piece
- Cut 1 side band piece
- Cut 1 brim piece (or 2 if lining/interfacing)
- Transfer notch points for accurate alignment
Step 4: Sewing Curved Seams Like a Pro
- Use a stitch length of 2.0 mm or less for control
- Pin generously, especially around curves—start with center and ends
- Clip inward curves, notch outward ones to ease bulk
- Go slow—use handwheel if necessary for tight turns
- Press seams with a tailor’s ham for clean shaping
Step 5: Assemble Your Hat
- Join the side band ends with ¼" seam allowance
- Attach band to crown: Match notches and ease curve into place
- Attach brim to bottom of band: Align notches, pin heavily, then stitch
- Press all seams and topstitch if desired
- Add finishing touches: bias tape binding, chin strap, or decorative ribbon
Flop with Flair
Your floppy sun hat is now ready to shade and shine! This project is fun, functional, and great for stash-busting summer fabrics. Feel free to play with color-blocking, embroidery, or fabric paint to personalize your look.
📸 Tag @SewlyJo or use #SewlyJoSunHat to share your creations—I’d love to feature your gorgeous makes!
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