How to Make a Bucket Hat

Bucket hats are a super easy way to keep the sun off while keeping style on. They are also light and allow you not to stand out too much, but also not fade away in a crowd! They could easily replace top hats as the most magical hats, though you sadly won’t be pulling any rabbits out of them!

These unique accessories can complete just about any outfit. You can add cute embroidered patches, pins, or even beads. Bucket hats are the perfect blend of sun protection and style. Crafting your own means a unique look that’s just your vibe.

With easy-to-follow steps, you’ll be flaunting a one-of-a-kind bucket hat that shows off your creativity.

There are a variety of bucket hats for you to choose from, but depending on the type of material used to make the bucket hat, you may or may not manage to make it yourself. The best bucket hat to make at home is the classic reversible bucket hat for casual wear. You can wear it for a day at the beach, a backyard party, or even while running errands around town.

This bucket hat is made using materials that are easy to work with such as cotton or linen. It is also extremely versatile because you can create totally different vibes with each side. 

Sewing a bucket hat takes around 2 to 3 hours . This time is a significant investment, but not something that will take an entire day. However, this duration depends on your sewing skills and experience. You will also need to invest some time procuring the best materials and equipment for the bucket hat adventure. The best idea is to collect the items, decide on a pattern, and set the working area a day before.

The best fabric for your bucket hat will majorly be determined by what you want to use the bucket hat for. If you want one that will protect you from UV rays (in conjunction with sunscreen!) you can use a tightly threaded cotton fabric . This fabric is best for breathability and comfort. Also, the tight threads will ensure fewer rays reach your face while the absorbent nature of the cotton will soak up the sweat.

For more durable bucket hats, denim and canvas are great choices. If you will be wearing it while doing water sports, collecting shells by the sea, or hanging out by the pool, waterproof materials like nylon are the best.

For a DIY bucket hat, easy-to-work-with materials such as cotton are best . However, you can try your hand at denim or canvas as they are only thicker than cotton but are similar to it (denim is essentially cotton).

To create your own bucket hat at home, here are the items you will need:

To be sure that you have everything you need when you start making the bucket hat, it is advisable to collect all these items a day or two before the day you plan on starting. Doing this will alleviate stress and allow you to get the best materials to bring your ideas to life.

To embark on your DIY bucket hat journey, you'll first need a pattern. A pattern is a template that guides you in cutting the fabric into the right shapes and sizes for assembly.

You have two options for obtaining a pattern: 

1. Find a Free Pattern Online: Numerous websites offer free bucket hat patterns. Simply search online for "free bucket hat pattern" to find a variety of options.

2. Create Your Own Pattern: This method offers the most flexibility and control over your hat's design. We'll walk you through the steps to create your own pattern below.

Draw the bucket hat’s design as shown below. These sections are labeled A, B, and C for the top curved part (which forms the crown), the center (which forms the sideband), and the bottom (which forms the brim), respectively.

Start by measuring your head to get the perfect crown size. Divide this measurement by π (3.14) to get the crown diameter. This diameter will guide you as you draft the hat’s top shape.

Great, now let’s get into designing part A. Use a ruler to draw a line on a white piece of paper. The line will serve as the diameter of the circle. The medium size for adults is 17cm in diameter. Extend the diameter by a 1cm allowance.

Place a compass at the center of the line and draw a circle. The circle forms the curve of your bucket hat. Draw two circles, an inner circle for the diameter of your head and an outer one for the 1cm allowance.

Use scissors to cut the paper around the outer circle. Select one hemisphere and measure the circumference of the inner part as shown in the picture below. Section B of your design needs to have the same measurement.

To design section B, cut a piece of white paper into a length similar to the circumference of the hemisphere. Use 8cm as the width. Divide the paper into four equal parts. Draw a line separating each part and cut through the line but don’t cut to the end. Leave the four parts still attached on one end.

Place these papers on a brown sheet of paper. With these parts still attached on one end, separate the other end by 1cm from one part to the other. Stick each part to the brown sheet using masking tape. The result should look like a slight curve.

Now, you need to design the seam allowance. Measure a 1cm extension around the four parts you’ve just attached to the brown sheet. Sketch around using a pen and a ruler.

Cut around the 1cm outer allowance.

Measure the inner white paper that forms the curve. Cut with that measurement as the length. Use 7cm as the width. Divide the paper into 8 equal parts, marking each boundary. Cut through the mark but don’t get to the end. You must leave each part connected to the other on one end.

Similar to how you did with section B, attach the 8 parts to a brown sheet using masking tape or adhesive vinyl. However, this time, you need to separate the other end by 1.5cm from one section of the 8 parts to the other.

Using a pen, draw a curved line around the 8 pieces of paper you’ve attached to the brown sheet. 

Cut around the line using a sharp blade.

Well done! Now you have the three shapes needed to make the bucket hat! Does what you have look like what is shown below?

Once you've finalized the design for your bucket hat, we can begin the process of bringing it to life. Here are the essential items you'll need to create a double-sided bucket hat.

With everything ready, we can proceed with the step-by-step production process.

The sections you create all resemble the final structure of the bucket hat. For an easier bucket-hat-making experience, line them up as shown below to help you see what you’re creating.

Place section C of your design (the one with 8 parts) on the adhesive batting. Trace around the design. 

Repeat this process on a different part of the batting so that you have two similar tracings that will give two similar cut-outs for section C.

Using scissors, cut the two parts you’ve just traced around.

Place the two pieces of adhesive batting on the fabric.

Now, you need to smoothen the materials. Place a soft piece of cloth on top and press with a hot iron box.

With the two pieces of adhesive batting on the fabric. Trace around each of them with a 1cm allowance.

With the two pieces of adhesive batting on the fabric. Trace around each of them with a 1cm allowance.

Place another piece of fabric on a flat surface with the fabric interfacing on top.

Place sections ‘A’ and ‘B’ on top and cut around as shown below.

Smoothen the fabrics by pressing with an iron box.

Place sections A and B on top of the interfacing fabric again and trace around. Make sure that the interfacing fabric is still on top of your main fabric. For section B, you need to trace two different parts of the fabric. Doing so will get you two pieces of fabric. For part A, just trace around once.

Cut around the traced sections using scissors ensuring that you cut both the interfacing fabric and the main fabric.

Place the pieces you’ve just cut (two section Cs, two section Bs, and one section A) on another piece of interfacing fabric. Cut around as shown below.

Ready your lining fabric and press it to ensure that it’s smooth. Place your interfacing fabric and all your design sections on top. Cut around each of your design sections. Insert about three pins in each design section to ensure that all materials are attached.

Separate the lining fabric for each section: A, B, and C.

Attach sections B and C then sew each 1 cm from each end.

You need to attach sections A to B. Attach the main fabrics and sew nicely around the edges together. Do the same for the lining fabric.

After sewing, your main fabric should look like this:

On the other hand, the lining fabric should look like this:

Now, focus on design C. Attach the lining fabric to the main fabric with the adhesive batting. Sew around the outer edge as shown below:

Flip the inner edge. Then sew all around in multiple lines.

Ready the main fabric forming the top part of the bucket hat (the section A and B you just sew). Then place the attached pieces inside section C.

Sew around the connected edges.

Ready the lining fabric that forms the top part of the bucket hat, then place it inside the sewed-together sections before sewing it around the edges again. Leave a small opening to turn back the outer parts of the bucket hat.

Place inside as shown:

Sew around the edges:

Leave a small opening:

Pull out the outer parts…and now you have a reversible bucket hat!

Iron both ends then ensure you close up the opening you used to pull it inside out.

Once you make your bucket hat, you will need to ensure that the washing process does not damage it. The reason extra care is needed is that when an item is made by hand and crafted from easy-to-work materials that are often delicate, it can easily lose its shape, fade, or become worn if not handled carefully.

So, you need to avoid harsh washing methods like the laundry machine and instead handwash it gently with a mild detergent. Avoid wringing or twisting it, which can distort its structure. Here again, you can gently knead it or rub it once drenched in detergent. If you must use a laundry machine, a mesh laundry bag will be your greatest ally.

From fashion to outdoor activities, bucket hats are exciting, vibrant, and trendy accessories to bring charm and personality to your wardrobe. Why not get a customized one you made with your own hands? You know everything you need to make that happen! There is also an irreplaceable satisfaction in wearing something you made yourself, according to your sensibilities.