Flat Cap Sewing Tutorial with Pattern

Flat Cap Sewing Tutorial with Pattern

Here is the full tutorial on how to sew the flat mens cap including drafting a pattern. This elegant men's flat hat can be in women's wardrobe also.

This flat cap sewing tutorial has a proven and accurate pattern, having standart men's size (58-60), will allow you to sew excellently fitting drivers cap.
If you want sew this cap for women or boys I recommend use stewart tartan or plaid fabrics.
This hat has lining from thin fabric, but if you want you can insert warm fabric. You can add folding inside earflaps to keep his ears warm when it's cold.

Consumption of fabric and lining

Consumption of fabric and lining

On this photo shows all parts of flat cap. But you should consider that you will also need to cut the lining and fusible interfacing also.
Consumption of fabric, lining, fusible interfacing is about 45 cm (17"). You need also a piece of ribbon for sewing inside of the back part of hat.
Based on my own practical experience, I know that you will need to adjust the hat circumference. The best way to do this is to add a piece of rubber on the back of the cap (inside).

How to draft a pattern of flat mens cap

How to draft a pattern of flat mens cap

In this section there are 4 photos of the real size of the flat cap pattern.
You need to save these images on your computer and print it.
On each photo there is a scale for checking the accuracy of the printed pattern.
Set up the printer if necessary before printing all parts of the pattern.

The top part of the header of flat cap pattern

The top part of the header of flat cap will be printed on two A4-size sheets of paper. You will need an adhesive tape to glue them together along the lines having mark "Connection line".

The side parts of flat cap pattern

Note: All details of the cap pattern are given with seam allowances (7 - 10 mm).

This pattern of visor

This pattern of the visor contains a pattern of plastic layer, that is used for inserting it between both parts of visor.

You will need to cut a strip 5 cm wide and 59 - 60 cm long depending on the circumference of the head.
Note: Grain line should be across the strip!

How to print pattern of flat cap

Before printing all parts of the flat cap, print one sheet (A 4) and check the accuracy of the size of this detail using the ruler.
With the help of adhesive tape it is convenient to glue both parts together.

All cap pieces must be have the fusible interfacing

The fusible interfacing

All parts of hat you need duplicate using the fusible interfacing. Only a long strip does not need to be double.

Flat cap seam allowances

Seam allowances should also be kept clean, as shown.

Beginning of sewing a gatsby hat

Beginning of sewing a gatsby hat

Start sewing this gatsby hat with joining these details together, as shown.

How to make finishing stitches

Next, make finishing stitches on these details, as shown.

Sewing all parts of cap together

Now it's time sew these parts together.

All curve sections need to be notch

All curve sections need to be notch.

Flat Cap Sewing Tutorial

This will allow to do well the finishing stitches along these seams.

How to make a seal layer for visor

How to make a seal layer for visor

Between both parts of visor you need insert some strong material that would hold the shape of visor. The simplest way is using plastic folder.
Note: The size of the plastic gasket is slightly smaller than the visor.

Making a visor of the flat cap

Making a visor of the flat cap

First, sew both parts together with seam allowance 7 - 8 mm.

How to trim the curve areas

Now take a scissors and trim along the curve 3-4 mm.

How to insert the plastic layer

Now turn out the visor and insert the plastic layer, as shown.

How to add the brim to the cap

How to add the brim to the cap

Before adding the visor you should stitch along inner area of visor.
Divide the visor on two part and mark this line.
Pin the visor to the front part of cap.

Now you need to sew along inner area of visor

Now you need to sew along inner area of visor with seam allowance 7mm.
Note: The needle should not pierce the plastic gasket.

This flat cap has a lining fabric

This flat cap has a lining fabric

The lining parts are identical to parts of cap. Use the cap's pattern for cutting lining.

Now insert the lining into the cap

Now insert the lining into the cap and pin it, as shown.

Now you need to stitch around the edge

Next, you need to stitch around the edge with seam allowance 7mm.

Last steps of sewing a flat cap

Last steps of sewing a flat cap

Wrap around the head the narrow strip and mark the place where will be sewing it together.
Stitch it together and trim the corners, as shown.

Now you need fold the edge of strip

Now you need fold the edge of strip ( 1 - 1.5 cm) and stitch the folded edge on wrong side, as shown.

Pin it with cap

Pin it with cap.

Now you can to sew this detail on sewing machine

Now you can to sew this detail on sewing machine.

How to trim the allowances around

To make this seam soft you need to trim the allowances around, as shown.

Flat cap finishing stitching

To fasten the strip with cap you need to do finishing stitching (from visor ends only).
Note: Don't sew along the visor!

How to add a piece of elastic strip

Based on my own practical experience, I know that you will need to adjust the hat circumference. The best way to do this is to add a piece of elastic strip on the back of the cap (inside).

The elastic strip can be installed inside

During sewing, the diameter of the cap may stretch. In this case, the elastic strip can be installed inside the back part of hat.

How to fasten the inner strip on the back seams

But if the diameter of cap is corresponded to the size of the head, then you do not need to insert a piece of elastic. You need to fasten the inner strip only along the back seams, as shown.

How the drivers hat looks inside

Now the flat mens cap is completed. On this photo you see how the hat looks inside.

How the flat cap looks from the front side

On this photo you see how the flat cap looks from the front side.

English isn't my first language, so please excuse any mistakes and help correct them.
E-mail for sending is on the contact page.

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