MARY Large Brim Sun Hat – Beginner Sewing Pattern

Looking for the perfect summer project? The MARY Large Brim Sun Hat Pattern is a fun, beginner-friendly pattern that lets you create your own stylish sun hat at home. Whether you're heading to the beach, relaxing in the garden or strolling around town, this hat is designed to keep you cool, comfortable and protected.

The wide brim gives you proper sun coverage for your face and neck while still looking chic. The crown is built from six shaped panels, which is what gives MARY its lovely rounded fit — and there's an optional fabric tie you can add as a hat band for a finishing touch.

Quick Facts (At a Glance)

  • Sizes Included: Two — Teenager 55cm and Adult 60cm
  • Construction: Six-panel crown with a wide, interfaced brim
  • Skill Level: Perfect for Beginners
  • Format: Digital PDF Download
  • Seam Allowance: ¼"

Materials Required

  • Outer Fabric: Medium weight cotton
  • Inner Fabric: Medium weight cotton
  • Interfacing: Medium weight iron-on interfacing for the brim
  • Optional 'Mary' Tie: Lightweight cotton, cut 140cm x 10cm (no template needed)
  • Essential Tools: Sewing machine, iron for pressing, clips and pins, a heat-erasable pen, and coordinating thread

What You Will Learn / Techniques

  • Cutting on the Fold: The brim pieces are cut on the fold — there's a video tutorial explaining this if you haven't done it before.
  • Building the Brim: Join outer and inner brim around the curve, stopping 5cm from each end, then turn, press and add a holding stitch.
  • Joining the Brim Ends: The fiddly bit — outer ends first, then the inner ends brought right sides together. Take it slowly and follow the video.
  • Six-Panel Crown Construction: Join the crown pieces one at a time, pressing each seam open as you go, for both outer and inner crowns.
  • Matching Brim to Crown: Mark four joining points on each so everything lines up evenly before you clip and sew.
  • Finishing: Leave a 10cm gap when joining the inner crown, turn the hat through, close the gap and press. Optionally sew concentric rings around the brim for a different look.
  • Making the 'Mary' Tie: Fold, sew and turn a long fabric tie to wrap around the crown as a hat band.

Why You'll Love This Pattern

  • Beginner-friendly — simple instructions, no stress
  • Stylish wide brim — the right balance of fashion and function
  • Real sun protection for your face and neck
  • Two sizes included: Teen (55cm) and Adult (60cm)
  • Optional fabric tie for a personal finishing touch
  • Reusable pattern — sew as many hats as you like in different fabrics

Full-colour step-by-step photographs, our trademark 'Easy to Follow Instructions' and full-size reusable templates are included, plus a free video tutorial on our YouTube channel to follow along with.

Step into summer with your own handmade sun hat — make one for yourself and one for a friend.

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