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Pillowcase Sun Hat

Turn an old pillowcase or less than a yard of scrap fabric into a feminine sun hat with this sewing tutorial from Stefi Luca. You can add bias tape for a colorful brim on this free hat sewing pattern.

Pillowcase Hat


  • Old Pillowcase or 1 yard of fabric
  • 1 yard of interfacing
  • bias tape


I refashioned mine from an old pillowcase but you can use any fabric, it only takes less than a yard. And you'll also need less than a yard of interfacing.


Start out by measuring your head size and replicate it on the fabric. To create a perfect circle divide the circumference of your head to 3.14 and then again to 2 to get the radius of the circle. Then mark the center of the circle on your fabric and with a ruler draw the circle. Think how big you want the brim to be and draw another circle around the first one.

Third piece of fabric you will need is a strip of the same length as the circumference of your head. Have the set of three pieces (2 circles and the strip) cut twice from the fabric and once from the interfacing.

Sew the edges of the strip together to form a crown. You'll have 3 crowns: 2 of fabrics and one of interfacing.

Sew together the outer fabric brim and the interfacing brim. Do the same with the outer fabric crown and the interfacing crown. Then sew the two sets together on the wrong side. It's not an easy stitch, I must say but be brave :)

Sew together the inner fabric brim and the inner fabric crown on the wrong side. Place the two brims with the attached crowns one inside the other and sew them together along the edges.

Sew the round sandwich together (fabric, interfacing, fabric) and then attach it to the crown on the wrong side. This isn't an easy stitch either but it's the last of the kind. Add a bias tape on the edge of the brim.

 Finished Pillowcase Sun Hat


You can also turn two pillowcases into a blouse with this tutorial.

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By: Stefi Luca My Dear Stefi Luca, Good work, great looking hat...You are so clever. Everyone has pillowcases. I just love hats. Have a wonderful Thanksgiving... Georgia

Very clever. I'll have to go through my supply of pillowcases. == A senior friend of mine converted baseball caps to sun hats by adding a new brim in place of the "bill" of the cap (she had a history of skin cancer on her face). Gay was a lifelong fan of the Baltimore Orioles who lived into her 80's (and is much missed by her family and many friends).

I just love this hat. Gives me that happy feeling...... Gail B

Cool hat! I could make and sell these. Sherry Ascough


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