Sew a sun hat in three head sizes — and make it reversible if you like

AVA MAY is a fully lined sun hat built from panels that join into a soft, packable shape. Because the outer and lining are complete hats in their own right, you can make it reversible — just close the turning gap by hand rather than by machine and you have two hats in one.

Choose a lightweight, breathable cotton and you'll have a hat that keeps the sun off and looks good doing it. Non-directional fabric works best.

What you'll learn

  • Folding and marking fabric to cut the panels accurately
  • Joining curved panel sections with a ¼" seam allowance
  • Matching the outer and lining seam-to-seam around the brim
  • Turning the hat through a gap in the lining and closing it by hand for a reversible finish
  • Topstitching the brim for a crisp edge

Finished sizes — head circumference

  • Small: approximately 20" / 51cm
  • Medium: approximately 22" / 56cm
  • Large: approximately 25" / 63cm

What you'll need

1m of medium weight cotton for the outer and 1m for the lining (non-directional fabric works best), G700 woven cotton interfacing (optional), and a heat-erasable pen for marking. Seam allowances: ¼" joining the panels, ½" around the brim.

Skill level

Beginner. Full-colour step-by-step photographs, our trademark 'Easy to Follow Instructions', and full-size reusable A4 templates for all three sizes — no enlarging required. A free video tutorial is available on our YouTube channel.

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