Prepare the flat cap

• Download and print the pattern for the desired hat.
  
  • Brown hat
  • Orange hat

• Cut out crown piece, 6 times, in exterior fabric.
   
• Cut out crown piece, 6 times, in lining fabric.
   
• Cut out brim piece, 1 time, in plastic.
   
• Cut out brim piece, 2 times, in fabric, leaving 0.6 cm (1/4-inch) seam allowance.
   
• Cut out rectangle measuring 60 x 3.8 cm (23-1/2 x 1-1/2 inches), 2 times, in exterior fabric.
  ! : Adjust this measurement to the head of the person you are making the hat for.
   
• Cut out same rectangle, 2 times, in lining fabric.

Crown of the flat cap

• Stitch 3 lining pieces together to form a half-circle.

• Stitch the other 3 lining pieces together to form a half-circle.

• Stitch the 2 half-circles together down the middle to form a circle.

• Repeat with exterior fabric.

• Pin the lining and exterior circles together, wrong sides together.

• Baste the 2 circles together around the edges.

Brim of the flat cap

• Sew the brim fabric pieces together, right sides together, along the outer edge.
  ! : Err on the smaller side with this step.
   
• Turn the brim cover right side out.
   
• Insert the plastic brim left to right, pinning the open edge as you go.
  ! : The fabric will stretch a bit.

• Baste along pin line.

Band of the flat cap

• Baste the 2 ends of the band together, right sides together, forming a circular shape.
   
• Check this band against the head of the person the hat is destined for.
  ! : The band should be a little loose, but not more than 2.5 cm (1 inch).
   
• Adjust as needed.
   
• Sew over basting stitches once measurement is sure.
   
• Sew brim to band, taking care not to sew through plastic but only through fabric.
  ! : This seam is easier to sew but harder to see if you position the brim underneath the band.

• Cut a piece of quilt lining to 2.5 cm (1 inch) longer than the band.
   
• Position an end of the lining at the center back along the bottom edge of the band (the same edge that the brim is on).
   
• Open the binding and fold the end and top edge down about 0.6 cm (1/4 inch).

• Stitch across the end and folded edges around the circle of the band.

• Cut off quilt binding and finish off stitching.
   
• Stitch around the circle again, this time along the bottom edge of the binding.

Assembly of the flat cap

• Pin crown to band, right sides together.
  ! : Don't worry if the measurements don't line up exactly; ease or stretch fabric a bit of they don't match.

• Stitch along the pin line.
   
• Bind the raw edges.
  
  • Fold the end of the binding down 0.6 cm (1/4 inch).
  • Stitch around the fold, following the previous stitching line.
    
  • Fold the loose edge of quilt binding over the raw edges.
  • Sew around the circle, making sure to sew over the folded seam you just stitched.

Variation

Add a pocket

• Cut a pocket piece from exterior fabric.
  ! : This should be taller than the finished pocket because the edge will be folded over.
   
• Fold the top of the pocket piece inside, about 1.3 cm (1/2 inch).
   
• Sew along left and right edges at 0.6 cm (1/4 inch) from the edge.

• Turn fabric inside out and stitch along the top to secure this newly-created flap.

• Stitch along rounded edge.
  ! : Gather stitching slightly to create a cleaner curve.

• Pin pocket to one of crown pieces.
  ! : It's easier if the piece with the pocket is in one of the middle sections of the crown half-circles.

• Stitch in place.

Source: Rachel