Western hat Sewing Patterns | DRCOS Patterns & How To Make

Free sewing pattern and tutorial for a Western-style hat, often called a “ten-gallon hat” in Japan, though technically different in design.

The PDF pattern includes seam allowance, so you can cut the fabric directly without adding margins. This pattern is suitable for both costume-making and casual fashion accessories.

For the best results, use a slightly stiff fabric to achieve a clean and defined shape. However, thick fabrics require a more powerful sewing machine, so beginners may want to start with a medium-weight material.

The construction includes a few steps that may be challenging for first-time hat makers. For highly detailed or professional-grade hats, consulting a specialist reference book is recommended, but this pattern is more than sufficient for everyday wear or self-made cosplay costumes.

Experiment with faux leather or unique textured fabrics for a fashionable twist. Adding eyelets and threading a decorative cord can enhance the Western style and make the hat more authentic.

After printing, align the joining lines, tape the sheets together, and cut out the pieces to begin sewing immediately.

Whether you are searching for a free Western hat sewing pattern, a cosplay cowboy hat tutorial, or a beginner-friendly PDF hat project, this pattern provides a stylish and versatile foundation for your next creation.

(1) Apply fusible interfacing to the top, side, and brim pieces.

(2) Sew the side pieces together, press the seam open, and topstitch.

* 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.

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

(5) Sew the two brims together along the dotted stitching line.

(6) Insert wire into the bias position of the brim and cover it with bias tape.

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

(7) Sew the brim and side together.

(8) Attach eyelets at the marked positions.

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

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