How to Sew Adult Bucket Hat

By Jeffery Keilholtz ; Updated September 15, 2017

Things Needed

  • Ruler
  • Cotton fabric (sizes will vary)
  • Standard chalk
  • Fabric scissors
  • Pinking shears
  • Needle
  • Thread
  • Ironing board
  • Iron
Wear a bucket hat to keep rain and heat off your head.

When the sun is in your eyes, and a baseball cap or visor is unavailable, it is time to pull out your bucket cap. Adult bucket caps are designed and assembled in the same manner as those made for children. Bucket caps are constructed from flexible, lightweight material and fit loosely and comfortably atop your head. The long sides and short brims of the hat give your head full coverage while keeping your eyes and face in the shade.

Measure the width of your head. Add 1 inch to the diameter of the width. Draw a circle to the adjusted width on a piece of cotton fabric with standard chalk. Draw a second circle – along with subsequent pieces – if you wish to give your hat a double layer.

Cut out the circle along the chalk lines with fabric scissors. Trim away any excess free-hanging fibers with pinking shears.

Lay the two circles one atop the other and sew them together using a straight stitch with a one-eighth inch seam allowance if you are double-layering your hat. Repeat this process for all subsequent pieces if you are double layering.

Place the circle atop a second sheet of cotton fabric. Trace half way around the outside edge of the circle. Trace a 4-inch perpendicular line -- one from the right end and one from the left end -- off each respective end of the tracing. Connect the ends of the perpendicular lines with a second curved line. The chalk outline should resemble a block letter "C" shape. Cut out and trim the edges of the C" shape. Repeat this step to create a second "C" shape. The 4-inch "C" shapes act as the sides of the hat.

Place the circle atop a third sheet of cotton fabric. Trace halfway around the outside edge of the circle. Trace a 1 1/2-inch perpendicular line -- one from the right end and one from the left end -- of each respective end of the tracing. Connect the ends of the perpendicular lines with a second curved line. The chalk outline should resemble a block letter "C" shape. Cut out and trim the edges of the C" shape. Repeat this step to create a second "C" shape. The 1 1/2 inch "C" shapes act as the brims of the hat.

Place the 4-inch side pieces face down onto an ironing board. Fold each 4-inch end 1/4 inch over its respective body. Iron the 1/4-inch sections to crease the folds.

Overlap the upper edge of one of the first 4-inch sides 1/8 inch over the circle -- so the bright sides of each piece are facing down. Stitch the pieces together using a straight stitch pattern. Overlap the upper edge of one of the second 4-inch sides 1/8 inch over the circle. Stitch the pieces together using a straight stitch pattern.

Press one 1/4-inch end of a 4-inch side against one of the 1/4-inch ends on the second 4-inch side so the bright sides of the fabric are facing each other. Stitch the 1/4-inch ends together using a cross-stitch pattern. Press one 1/4-inch end of a 4-inch side against the remaining 1/4-inch end on the remaining 4-inch side. Stitch the 1/4-inch ends together using a cross-stitch pattern.

Stitch the upper edge of the first 1 1/2-inch rim to the bottom edge of one of the 4-inch sides -- with a 1/4-inch seam allowance -- using a straight stitch pattern. Stitch the upper edge of the first 1 1/2-inch rim to the bottom edge of the remaining 4-inch sides -- with a 1/4-inch seam allowance -- using a straight stitch pattern. Turn the hat inside out before wearing.

About the Author

Jeffery Keilholtz began writing in 2002. He has worked professionally in the humanities and social sciences and is an expert in dramatic arts and professional politics. Keilholtz is published in publications such as Raw Story and Z-Magazine, and also pens political commentary under a pseudonym, Maryann Mann. He holds a dual Associate of Arts in psychology and sociology from Frederick Community College.