A bucket hat is one of those projects that’s quick, useful, and a little addictive. You only need a small amount of fabric, and you end up with a hat you’ll actually wear. If you’ve been wondering how to sew a hat, this is a great place to start.
In this guide, we’ll show you how to make a bucket hat with our Bucket Hat Sewing Pattern: what you need, how to pick your size and fabric, and how the hat comes together.
Prefer to watch? Christina sews the whole hat in our free YouTube sew-along.
The sewing pattern at a glance
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Skill level: 2 out of 4, great for adventurous beginners
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Sizes: 2XS to 3XL, for head circumferences from 20.5 to 25.25 in (52 to 64 cm), so it works for both kids and adults
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Details: fully lined, decorative band, stitched brim with binding, and two brim shapes to choose from
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Format: PDF pattern in US Letter, A4, A0 copy shop file, and projector file, with seam allowances included
Watch the bucket hat tutorial on video
Want to see how to sew a bucket hat before you start? In this bucket hat sewing tutorial, Christina goes through the materials, cutting, sewing the band and brim, and attaching the lining.
Keep this guide open next to you for a quick reminder of each step.
What you’ll need
- The Bucket Hat Sewing Pattern
- Medium-weight woven fabric for the outside, like canvas, cotton drill, or denim
- Lightweight woven fabric for the lining
- Medium-weight stiff interfacing
- Matching thread
- Sewing machine
- Fabric scissors, pins or sewing clips, and a tape measure
- Optional: two snaps and four eyelets
You’ll find the exact fabric requirements for each size in the pattern.
The best fabric for a bucket hat
Go for a medium-weight woven fabric. Canvas, cotton drill, and denim all give the hat enough body to hold its shape, and twill and corduroy work well too. Got an old pair of jeans you don't wear anymore? They make a great DIY bucket hat.
For the lining, pick a lightweight woven fabric. You can match it to the outside for a classic look, or choose a contrasting print for a fun surprise inside the hat.
Since a bucket hat only uses smaller pieces of fabric, it's also a nice way to use up what's left in your stash.
Soft or structured? Choose your interfacing
The pattern calls for a medium-weight stiff interfacing, which gives the brim a nice shape. You can adjust it to get the look you want:
- Lighter interfacing gives you a softer, more relaxed bucket hat.
- Medium-weight interfacing gives you the classic look.
- Heavier interfacing gives you a crisp, structured safari hat.
If you can, test your fabric and interfacing together on a scrap before you cut your final pieces. That way you'll know exactly how the hat will feel.
How to make a bucket hat – step by step
Here’s how the hat comes together. The pattern has fully illustrated instructions for every step, and you can follow along in the video at the same time.
Step 1: Measure your head
Wrap a tape measure around the widest part of your head, right where the hat will sit. Keep one finger under the tape so it isn’t too tight.
Step 2: Pick your size and brim shape
Compare your measurement with the size chart in the pattern.
A bucket hat should sit comfortably without squeezing, so if you’re between two sizes, go with the larger one. Then choose which of the two brim shapes you’d like to make.
Step 3: Cut your fabric
Print the pattern in your size (the layers let you print just the size you need) and cut your pieces from the main fabric, lining, and interfacing.
Seam allowances are already included, so there’s nothing to add.
Step 4: Sew the band and brim
This is where your hat starts to take shape. Some of the pieces have opposite curves that seem to work against each other. That’s completely normal! Use plenty of pins or clips, spread the fabric out evenly, and sew slowly around the curves.
Taking your time here gives you smooth seams and a neat, professional finish.
Step 5: Attach the lining
Next, the lining goes in. It makes the hat comfortable to wear and gives it a clean finish on the inside.
Step 6: Add the finishing details
Finish the hat with the stitching on the brim and the binding around the edge. If you like, add snaps and eyelets at the end. And that's it: your bucket hat is ready to wear!
One pattern for the whole family
Because the pattern covers sizes 2XS to 3XL, you can sew hats for everyone, from young kids to adults. Make a light summer hat, a sturdy denim hat for every day, or a structured safari hat for hiking and travel. Just changing the fabric gives you a whole new look.
Once you've made one, it’s hard to stop. Bucket hats make great handmade gifts, and matching family hats are always a hit. Want another quick way to use up leftover fabric? Try our guide on how to sew a fabric bag with leftover fabric.
Frequently asked questions about DIY bucket hat patterns
What is the best fabric for a bucket hat?
A medium-weight woven fabric, like canvas, cotton drill, or denim, for the outside, and a lightweight woven fabric for the lining. Twill and corduroy are good options too.
How do I measure my head for a hat?
Measure around the widest part of your head, where the hat will sit, with one finger under the tape. Then compare the number with the size chart in the pattern.
How should a bucket hat fit?
It should sit comfortably on your head without feeling tight. If your measurement falls between two sizes, choose the larger size.
Is it hard to sew a bucket hat?
Not if you’ve sewn a little before. The pattern is rated 2 out of 4, so it’s a good next step for adventurous beginners. The trickiest part is the curves, and the video shows you exactly how to handle them. Brand new to sewing? Start with our guide on how to start sewing.
Can I make a bucket hat for my kids?
Yes! The pattern fits head circumferences from 20.5 to 25.25 in (52 to 64 cm), so the same pattern works for kids and adults.
Ready to sew your bucket hat? Let’s go!
Get the Bucket Hat Sewing Pattern, find a fabric you love, and sew along with Christina on YouTube. The bucket hat is one of our unisex patterns, and you can find more of them in our complete guide to unisex sewing patterns. Ready for colder days? The Beanie Hat Sewing Pattern is a quick and cozy next project.
