Free sewing pattern and tutorial for a round-style Western hat, inspired by vintage designs and suitable for both fashion and costume-making.
The PDF pattern includes seam allowance, so you can cut the fabric directly without adding margins. This pattern works well for everyday wear, cosplay costumes, or as a stylish handmade accessory.
For a crisp and defined shape, use a slightly stiff fabric. However, thick fabrics require a more powerful sewing machine, so beginners are encouraged to start with a medium-weight material for easier handling.
The construction process includes a few steps that may be challenging for first-time hat makers. For highly authentic or advanced designs, referring to a specialist millinery guide is recommended. Nevertheless, this pattern is more than sufficient for casual wear and cosplay projects.
Experiment with faux leather or unique textured fabrics for a fashionable finish. Adding eyelets and threading a decorative cord will enhance the Western aesthetic and give the hat an authentic touch.
After printing, align the joining lines, tape the sheets together, and cut out the pattern pieces to start sewing right away.
Whether you are searching for a free Western hat sewing pattern, a vintage cowboy hat tutorial, or a beginner-friendly PDF hat project, this guide provides the perfect base for your next handmade 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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44cm
head size 44cm 4sheets of A4 size(or legal size)
5 1/2(17.3in)
head size 17.3in 4 sheets of letter size
46cm
head size 46cm 4sheets of A4 size(or legal size)
5 3/4(18.1in)
head size 18.1in 4 sheets of letter size
48cm
head size 48cm 4sheets of A4 size(or legal size)
6(18.9in)
head size 18.8in 4 sheets of letter size
50cm
head size 50cm 4sheets of A4 size(or legal size)
6 1/4(19.6in)
head size 19.6in 4 sheets of letter size
52cm
head size 52cm 4sheets of A4 size(or legal size)
6 1/2(20.4in)
head size 20.4in 5 sheets of letter size
54cm
head size 54cm 5sheets of A4 size(or legal size)
6 3/4(21.2in)
head size 21.2in 5 sheets of letter size
56cm
head size 56cm 5sheets of A4 size(or legal size)
7(22in)
head size 22in 5 sheets of letter size
58cm
head size 58cm 6sheets of A4 size(or legal size)
7 1/4(22.8in)
head size 22.8in 5 sheets of letter size
60cm
head size 60cm 6sheets of A4 size(or legal size)
7 1/2(23.5in)
head size 23.6in 5 sheets of letter size
62cm
head size 62cm 7sheets of A4 size(or legal size)
7 3/4(24.3in)
head size 24.4in 6 sheets of letter size
64cm
head size 64cm 7sheets of A4 size(or legal size)
8(25.1in)
head size 25.1in 6 sheets of letter size
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