Greystoke Sun Hat July 27, 2021 18:13

Here's the instructions for my Greystoke Sun Hat Sewing pattern, this design has a nice deep cap and really wide brim for extra sun protection (or so people can't see you rolling your eyes).

This pattern comes in 5 sizes from XS (48cm) - XL (60cm) so that you can also make for older children, tbh my kids kept stealing the sample so I thought it might be a winner in all sizes.

To make this project you will need some light to medium weight woven fabric in 2 nice designs because this beauty is REVERSIBLE. And you will also need some heavy interfacing for the wide brim. 

Here's how to make the #Greystoke Sun Hat and some top tips for success.


Kit List:

MATERIALS

TOOLS

Freckles and Co Greystoke Sun Hat sewing pattern

Grab the PDF pattern templates in my Pattern Shop

Also see illustrated instructions below which you can choose to print or not (you could save paper/ink and view the illustrations on screen).

Freckles and Co Greystoke Sun Hat sewing pattern



Let's get started!

Firstly cut out your pattern templates and for this one you will need to print x4 of the brim template in order to stick them together so that you can cut each brim on the fold.

Freckles and Co Greystoke Sun Hat sewing pattern

Next gather all your materials and, cut out your fabrics and choose your threads.

This pattern INCLUDES 1/4" seam allowances

(1) CUT OUT all your pieces in total - Cap x12 / Brim x2 on fold

Freckles and Co #greystone sun hat sewing pattern tutorial

(2) Fabric 1 - Construct the cap by joining 6 segments together

Join 3 pieces twice and then join the 2 halves to make one cap. Press seams open after every seam for best finish.

Freckles and Co #greystone sun hat sewing pattern tutorial

Freckles and Co #greystone sun hat sewing pattern tutorial

(3) Fabric 1 - Stiffen the BRIM with heavy weight interfacing fusible (iron on) or sew in. Use your fabric brim as a template for interfacing.

The brim on this design is wide so it needs help to prevent excess flopping.

Freckles and Co #greystone sun hat sewing pattern tutorial

TOP TIP when using fusible cut the interfacing slightly smaller than the fabric so as not to fuse to your ironing board/mat.

Freckles and Co #greystone sun hat sewing pattern tutorial

(4) Join CAP to BRIM using notches to align.

Freckles and Co #greystone sun hat sewing pattern tutorial


(5) Repeat all above steps with with fabric 2 to make a second hat.
 
(6) JOIN hats RST (right sides together) sewing all around outer edge of the brims.

Leave a 4" gap to turn the hat through. Be sure to backstitch (reverse) at beginning and end of seam otherwise you will rip open the seam when turning through next.

Freckles and Co #greystone sun hat sewing pattern tutorialFreckles and Co #greystone sun hat sewing pattern tutorial

Turn your hat through the right way out. This will seam impossible but go slow and be patient. 

Freckles and Co #greystone sun hat sewing pattern tutorial

Try it on for fit and to check all seams before closing up the gap 

Freckles and Co #greystone sun hat sewing pattern tutorial 
PRESS gap seams in, try to round the edge as best as possible.

Freckles and Co #greystone sun hat sewing pattern tutorial 


(7) Top stitch edge of brim with long stitch length (5mm) use a twin needle if you have one. And then top stitch inner brim through all layers to really secure the two hats together.

I hope that you like this pattern as much as I do, share your creations with me on Instagram #greystokesunhat #frecklessewingpatterns

Looking for more sewing patterns?

See me making the Greystoke on You Tube