Tutorial ~ Sunhat With A Bias Tape Brim

by Destri on August 2, 2010

Are you ready for another sunhat tutorial?  While there may be better instructions out there for making that bucket portion of the hat, I wanted to show you a fun way to make a brim that adds a different element than just fabric.  Bias Tape!  And it is so easy, it was actually the easiest part.  That might have been due to the fact that I was totally winging it when it came to the body of the hat, but had I found this tutorial on Sew Much Ado sooner I would have used it, just sayin. But for the sake of this tutorial, and in case you need a larger size I will show you how I did both parts.  Let’s get started!


  • all your sewing stuff
  • double fold bias tape


  • I used fabric scraps.  I actually even had to sew together strips to make the body.  Use what you have ladies!
  • fabric for the lining


Measure the head by wrapping a tape measure around the head right above the eyebrows and ears.  Take that number and add an inch.

Fabric Cuts:

So here comes the part that I was winging it.  I just used a bowl to cut out the circles for the top then cut the strips to be the length of my measurement for the length.  I made the width 4 inches, but I would do 3½ next time.  Make sure you have the same cuts for the lining.


Start by sewing the short ends of your strips together right sides in, making to rings.

Next you are going to pin the rings to the circles like shown.  I just pinched and pinned around, but I have seen where they cut notches, again…winging it!

Now sew the two together using a ½ inch seam allowance.  Repeat for the liner.  Now turn the body right side out and tuck the liner inside leaving it right side in.

Now take bias tape and fold over the raw edges of the body and lining and sew around the perimeter. When you reach the end just fold the bias tape under a little.

This is the bucket of your hat! Now onto the brim….

Take the entire length of the bias tape and fold one end in like shown.  Make a ring the same size as the ring of your bucket. This is where you will begin sewing.  You will use a small zigzag setting and follow all around the circle, lining the bias tape right against itself…

Like shown in this picture.  Does that make sense?  So you make a ring the same size as the bucket, with the entire length still hanging, and then just begin sewing around till you reach the size of the brim you want.  Fold the end under at the end.  I promise it will make sense once you start going!

Now sew a single ring of bias tape around the top, folding the end under.

It should look something like this.

Now take your bucket and sew it to the brim using a small zigzag stitch.  Just line them right up next to each other and sew around.  You’re done!

I am making a shirt to go with it and this skirt, and so you will get to see some pictures of the hat in action….hopefully Saturday.

Questions?  Leave them in the comments!

Print Friendly
  • Facebook
  • StumbleUpon
  • Twitter
  • RSS

{ 18 comments… read them below or add one }

Courtney August 2, 2010 at 8:42 am

super cute! how creative!


Rachel August 2, 2010 at 12:41 pm

That is so cute! I love that brim! Thanks so much, I’ll be linking.


brenbren August 2, 2010 at 5:49 pm

I LOVE it!


Anne August 3, 2010 at 5:52 am

Love that bias tape brim!! I linked to your tutorial over at Craft Gossip Sewing:



Abby @ Sew Much Ado August 3, 2010 at 9:06 am

Oh my goodness, that hat is absolutely adorable! I LOVE the bias tape brim, that is such a fun idea! And thanks for linking to my pattern, maybe one day I’ll actually get the patterns done for more sizes :).


Suzanne August 3, 2010 at 11:07 pm

This is so adorable can’t wait to see the outfit you come up with it!


Dawn Buscher August 5, 2010 at 12:13 pm

Love this! Definitely a fun weekend project.


AnneMarie August 9, 2010 at 12:15 pm

Love the hat! We are posted right next to each other on Made by You Monday, and I thought, did we use the same material? I don’t think you used oilcloth. But that is SUPER cute!! I love that you used scraps too. Great use for ready to go bias tape too.


Jennifer September 21, 2010 at 11:36 am

This is such a cute hat! Great tute! Thanks! I linked you to my blog: http://aworldofcrafts.blogspot.com/


Frances October 25, 2010 at 1:49 pm

Really gorgeous hat, great job! Have tried myself, and the crown looks great, although for some reason the bias binding bit is ending up as one big completely even tube, and not flaring at all – am I missing something here?? Thanks in advance


Kelli July 5, 2011 at 4:22 am

Wow! Too cute. I love the idea. Of using bias tape…different and fun! Great job. Came over from SMS.


Bernadette September 2, 2011 at 7:48 pm

It looks great and especially with the pretty rosette on the side to dress it up. Will have to try and make one of those. I do wear hats.


Aly December 26, 2011 at 7:40 pm

Thank you for sharing, I too like one of the posts above must be missing something with the brim… mine looks like a big cylinder and not flaring at all. Any advise you could give that would be great.


Destri December 27, 2011 at 7:14 am

Hi Aly, I heard back from her, I should of asked how she adjusted her tape. I would make sure that you have the brim flattened a bit while you sew it. If it is allowed to just rotate around the base of the machine you would get more of a cylinder. I need to make another one so I can describe that better! Let me know if that makes sense and I will see if I can work on one today…I have an itch for sewing so that ought to satisfy it :)


Rachel H April 30, 2013 at 7:20 am

I love this tute – I have a massive head so really struggle to find hats that fit- usually I crochet or knit ones. This will be perfect – thanks for sharing


Aurora Boggs June 8, 2013 at 11:46 pm

This is such a cute Hat:-)


Kathy Van July 15, 2013 at 2:12 pm

Hi…too cute. I’m 2 weeks into a 12 week chemo schedule. At day 12, hair loss started. My hat wardrobe will be expanding & this is a must have! Thanks!


Rosemary Byrne July 19, 2013 at 9:08 pm

How lovely of you to make yourself a hat–taking positive action when faced with a very difficult situation. I wish you the best with your chemo! Sending good vibes in your general direction….


Leave a Comment

{ 2 trackbacks }

Previous post:

Next post: