Western hat Sewing Patterns | DRCOS Patterns & How To Make

This is a sewing pattern and tutorial for a Western hat.

In Japan, it is often called a “ten-gallon hat,” but that term is not technically correct.

It is better to use slightly firm fabric to create a beautiful silhouette. However, if the fabric is too thick, you will need a sewing machine with enough power, so beginners should start with medium-weight fabric.

Some steps in the process may be a little challenging. For a professional-level finish, you may want to refer to specialized books. Still, this pattern is practical enough for daily fashion or handmade cosplay costumes.

You can also make it stylish by using faux leather or unique fabrics. It looks cool when you use eyelets properly and thread a cord through them.

After printing, align and paste the pages along the matching lines, then cut along the outline. Seam allowances are already included, so you can use the pattern as it is.

(1) Apply fusible interfacing to the "Top", "Side", and "Brim" pieces. Use the "top interfacing (heavy weight)", "side interfacing (heavy weight)", and "brim interfacing (heavy weight)".

(2) Sew the "Side" pieces together. Press the seam open with an iron and topstitch along the seam.

* Trim the seam allowance if necessary.

(3) Sew the "Top" and "Side" together. Press the seam open and topstitch.

* Trim the seam allowance if necessary. Do the same for both outer and lining.

(4) Sew the "Brim" pieces into a loop. Press the seam open and topstitch along the seam.

* Trim the seam allowance if necessary. Do the same for both outer and lining.

(5) Sew the two "Brim" pieces together along the dotted stitching line.

(6) Insert wire along the bias position of the "Brim" and cover it with bias tape.

* It is better to tack the wire onto the seam allowance to keep it fixed in place.

(7) Sew the "Brim" and "Side" together.

(8) Attach eyelets at the marked positions.

(9) Thread the cord through the eyelets and attach the loop end to complete.

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