M

N

1. CUT OUT PATTERN PIECES. Using the pattern online, cut out 1 hat top, 2 hat sides (each cut on a fold), and 2 brims (each cut on a fold), from a large sheet of fused plastic (Figure J).

Finger-press open the seam allowances and topstitch them open on either side of the seam line. Repeat for the second seam.

Fold a ¼" hem around the perimeter of the brim. Pin and topstitch 1" from the fold (Figure M).

2. SEW THE SIDES TOGETHER. Place the 2 hat sides right sides together, and seam the ends using a ¼" seam allowance (Figure K). Press open the seam allowances with your fingers, and topstitch them open on either side of the seam line. Repeat for the second seam.

5. JOIN THE BRIM TO THE SIDES.

Photograph by Garry McLeod (ensemble)

With right sides together, align the side seams of the hat sides with the seams of the brim. Distribute the material evenly, pinning the bottom edge of the hat sides to the inside curve of the brim. Stitch using a ¼" seam allowance.

3. JOIN THE TOP TO THE SIDES. Flip the brim down and finger-press the seam Fold the hat top in half and mark the halfway points allowances up toward the inside of the hat. with pins. With right sides together, align these pins Edge-stitch the seam allowances to the hat sides, with the side seams of the sewn hat sides, along the 1" from the seam. top edge. Distribute the material evenly, pinning the top edge of the hat sides to the hat top (Figure L).

Stitch using a ¼" seam allowance.

4. SEW THE BRIM.

Place the 2 brim pieces right sides together, and sew the ends using a ¼" seam allowance.

6. ADD A BAND.

Apply waterproof glue around the seam where the hat sides meet the brim and press a length of ribbon (about 25") into place to create a hatband (Figure N). Allow the glue to dry. ×