How to make a bucket hat

1. Materials & tools

Materials (adult size)

• Main fabric (cotton, linen or canvas) — about 60 × 60 cm (24 × 24 in)
• Lining fabric — the same amount
• Fusible interfacing — for the brim
• Optional: a cord and eyelets for a chin strap

Tools

• Sewing machine (or needle and thread)
• Fabric marker or pencil
• Ruler and scissors
• Iron
• Pins or clips

2. Make the pattern (auto-generated in Katagami)

With the Katagami pattern tool, you just enter the finished size and it drafts a seam-allowance-included pattern, tiled to print at actual size on Letter or A4.

1. Open the tool
   Open the pattern tool and choose “Accessories” → “Bucket hat” from the tabs at the top.
2. Enter the size
   Enter head circumference, crown depth, brim width and ease. Presets cover child, adult and large.
3. Set the seam allowance
   Use the slider at the bottom (beginners: 1.0–1.5 cm / about 3/8–5/8 in).
4. Print
   Press “Print (actual size)”, then in the print dialog set Scale = 100% and turn “Fit to page” OFF. Check the 50 mm calibration box on the first guide sheet with a ruler.

3. Cutting the fabric

1. Trace the pattern
   Trace the crown (a circle), the side band and the brim (a ring).
2. Cut
   Cut each piece in both main and lining fabric. Fuse interfacing to the brim pieces.
3. Finish the edges
   Not needed if you are lining it.

4. Sewing

4-1. Make the brim

1. Sew the two brim rings right sides together along the outer edge.
2. Clip the curve, turn and press. Topstitch concentric rings across the brim — that is what makes it hold its shape.

4-2. Make the crown and band

1. Sew the side band into a loop, then sew the crown circle to its upper edge.
2. Pin at four points first, then fill in between. Starting at one end guarantees you run short at the other.
3. Assemble the lining the same way.

4-3. Assemble

1. Pin the brim to the lower edge of the outer band, right sides together, and sew.
2. Slip the lining over it, right sides together, and sew around the same edge, leaving a gap.
3. Turn through the gap, close it, push the lining inside and topstitch around the base of the crown.

✏️ Every seam here joins two circles. Pin at four points, then halve the gaps, then halve again. Sew from one end and the last few centimeters will never match.

5. Tips & variations

• Interface the brim: without it the brim flops and the hat looks unfinished.
• Reversible: use two good fabrics and it works either way out.
• Add a chin cord: two eyelets and a cord keeps it on in wind, which matters for children.