You never know when you'll need a pirate hat. Luckily for you, I've come up with this awesome pirate hat making tutorial. So, let's make a pirate hat, shall we?
This hat is made from 100% cheepo, polyester felt.
Disclaimer: I'm sure there are ways to mathematically calculate the sizes and shapes of the pattern pieces, but you won't find them here. I am scary bad at math, so let's not go there.
Step 1: Take cranium measurements. Measure for head circumference and for the depth of the hat. Think from the top of the ear to just over the top of the head. Make sure the measuring tape is nice and loose when you measure around the head. Otherwise you will have a brain constrictor on your hands, and no one wants that.
Step 2: Mark and cut out felt. Add 1" each to your depth and circumference measurements. This will give you 1/2" seam allowance. Draw and cut a rectangle from those measurements.
Sew a 1/2" seam down the narrow side of the rectangle, making a short cylinder.
To create the top of the hat, trace this cylinder. Add 1/2" around the outside for seam allowance. Cut out.
Next cut a big circle. I mine was 17" across to begin with. You can always trim it down if it is too big. If you cut it too small, then you will just be stuck with a stupid looking hat.
Fold your circle in quarters and cut a small circle from the middle. The circle needs to be way smaller than you think it should be. I think I started with about 4". Once again you can make the circle larger later if you need to. Remember, I am bad at math.
Step 3: Make the crown of the hat. Pin the top of the hat into the cylinder. It's ok to allow a little extra fabric between the pins. Notice how mine looks "ruffly." Sew the pieces together with a 1/2" seam. Adjust the fabric as you go to prevent "pleats."
Now would be a good time to check the fit of the hat.
Step 4: Sew on the brim. Fit the crown of the hat inside of the hole in the center of your big circle of felt. It should look like a very tight fit, or even like it won't fit in there at all. Pin it, allowing the felt to stretch if it needs to. If it really, truly doesn't fit, now is the time to make your hole bigger. Do this a LITTLE at a time. Once it's too big, you are out of luck.
Sew the brim to the crown with a 1/2" seam.
Now sew down that seam into the crown of the hat. use the edge of the presser foot as a guide, and stitch next the the seam you just created.
Step 5: Make a cool applique. Draw a goofy looking skull and then take a really blurry picture of it, if you feel the need.
Cut out your applique and stitch it down.
Step 6: Finish the brim. Pin up the brim on 3 sides. If it is too long, you will need to trim it.
Add something along the edge of the brim. I just used a 1" wide strip of felt with my bias binding foot.
Tack up 3 sides of the brim, pirate style.
Now repeat the five "A's": Arrrg! Avast! Ahoy! Ayyy! Ai-Ai!
Captain No Beard and First Mate Stinkypants