Free Bucket Hat Sewing Pattern

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Learn how to make a bucket hat with a free sewing pattern in baby, child, and adult sizes. This beginner sewing project is great for summer!

Summer is here, and I love spending time outdoors. We love to hike, garden, and swim so having a hat to keep our face shaded and protected from the sun is so important.

I started designing this hat as a bucket hat, but I widened the brim for more sun coverage. It’s almost more of a sun hat, but I’m still calling it a bucket hat.

This hat comes with one design, but it comes in 9 sizes from baby to child to several adult sizes. It works for the whole family!

Free Bucket Hat Sewing Pattern

What fabric works for a bucket hat?

The fabric that works best for a bucket hat is cotton canvas or quilting cotton. I used both for the two hats I made with great success. The canvas makes the hat a little bit stiffer, but it also makes the hat a little harder to sew.

Canvas and cotton are easy to find and easy to sew, and it comes in every print and color imaginable. You’ll also need a fat quarter of quilting cotton for the lining.

Should I prewash the fabric?

Yes, you should prewash the fabric. Since the hat will get used and it’s washable, you should wash and dry the fabric on hot before cutting out the pattern pieces.

Free Bucket Hat Sewing Pattern

What is a PDF sewing pattern?

A PDF pattern is a sewing pattern designed on the computer and organized so that it can be printed on several letter or A4 size pieces of paper.

I love using PDF sewing patterns because if the pattern gets ruined or if my children or I changed sizes, I can always print it again. It’ll never be destroyed since I have a digital version!

How do you use a PDF sewing pattern?

Open the PDF on a computer and click print. When printing make sure that the scaling is set to 100% or no scaling so that the pattern prints at the correct size.

Once the pattern is printed it can be taped together to get the full size. Then the pattern can be cut for each pattern piece size or individual sizes can be traced so that the pattern can be used again and again.

Free Bucket Hat Sewing Pattern

What sizes does the pattern come in?

The pattern comes in sizes baby, toddler, young child, child, teen, and four adult sizes. Use the measurement chart below to find the right size to make.

When you measure your head, make sure you are measuring around the widest part of your head so that you make the right size.

bucket hat pattern sizes

Do you love to sew? Try one of these fun sewing projects:

Free Bucket Hat Sewing Pattern

How to Make a Bucket Hat


  • 1/2 yard quilting cotton or cotton canvas (for the main part of the hat)
  • 1 fat quarter of quilting cotton (for the lining of the hat)
  • 1/2 yard fusible interfacing
  • Matching thread
  • Sewing tools
  • Sewing machine
  • Free Bucket Hat Sewing Pattern – get it at the end of the post behind the locked content box

Do you just want the pattern and tutorial as a PDF? Get the pattern and photo tutorial for just $4. You won’t need to access the internet every time you want to make it. Or get the Pattern Bundle with ALL the PDF tutorials!

Free Bucket Hat Sewing Pattern

Cut out all the pattern pieces as instructed in the pattern. From the outer fabric you’ll need 1 crown, 2 sides, and 4 brims. From the lining you’ll need 1 crown and 2 sides. From the interfacing you’ll need 1 crown, 2 sides, and 4 brims.

Fuse the interfacing pieces to all the wrong side of the outer fabric pieces.

Match up the short sides of the outer fabric sides with right sides together. Match up the shorts ides of the lining fabric sides with right sides together. Sew each side and backstitch when you start and when you stop.

sew sides of sides right sides together

Press the seams open.

On the outer fabric side (that is now a tube), edgestitch the seam allowances open. This creates a nice, casual look and makes it easier to sew and wear with the seam allowances stitched flat.

press and topstitch seams open

Pin the crown to the top (the smaller circumference) of the side with right sides together and match the notches to the side seams. Sew the crown to the side being careful since you’re sewing a curve to a straight edge.

Do the same to the lining. Press the seam allowances towards the crown on both the outer piece and the lining piece.

Edgestitch the seam allowance towards the crown on the outer hat piece.

Sew around the bottom of the lining piece 3/8 inch from the edge. This is a guide stitch.

press and topstitch seam towards brim

Pin one brim to another at the short side seams with right sides together. Pin the other brim to the remaining brim with right sides together.

Sew all four side seams and backstitch when you start and when you stop.

sew sides of brims right sides together

Press the seams open. Edgestitch around the seam to keep the seam allowance open and flat.

press and topstitch seam open

Place the brims right sides together and match up the outer circle. Pin it together.

Sew the outer edge of the brim all the way around.

sew outer edge of brims right sides together

Notch the seam allowance or trim it with pink shears.

notch outer seam

Turn the brim right side out and press flat.

turn brim right side out

Topstitch around the edge of the brim 1/4 inch from the edge.

Optional: sew more rows of stitching in smaller and smaller circles around the brim. This just adds to the look.

press and topstitch the brim

Pin the brim to the side with right sides together. Match up the side seams of the brim with the sides seams of the sides.

Sew the seam. Be careful and adjust as you sew since you’re sewing a curve to a straight edge.

sew brim to side and top

Clip 1/4 inch into the seam allowance with scissors about every 1 inch.

clip seam allowance

Place the lining inside with the wrong side of the lining facing the wrong side of the hat. Fold the lining inside at the 3/8 inch guide stitch. Pin the lining in place with all the raw edges folded inside.

put lining inside hat with wrong sides together
fold edge under and pin

When looking at the hat from the outside, sew in the seamline between the brim and the side to secure the lining inside.

sew around side from outside to secure lining

You finished!

Free Bucket Hat Sewing Pattern

Get the Free Sewing Pattern Below!

Get the Free Bucket Sewing Pattern

If you make something using this sewing project, I’d love to see! Please share it on social media with the hashtag #heatherhandmade and tag me!

Free Bucket Hat Sewing Pattern

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Hola, I have had many problems trying to fit everything… I am very desperate and disappointed. I hope you can help me

I have a question about the sizing. I made an adult small. before i measured my head. it is way too big. but after i measured my head it equals a child size. is that correct? i love the pattern though. it was pretty easy to sew. and it looks great. i just want to know what size i should make. because i need this floppy hat. thanks.

I can’t even find the bucket hat pattern to print as there are all sorts of stuff on the webpage and no easy way to find it unless I am just not seeing it.

I would like to know if anyone else has successfully followed this pattern? I have tried 3 times – 3 different sizes – and I get the same problem every time. I cut and assembled the patterns correctly, but the sides end up too long for the top, and then after I either trim them down (by 2″) or gather them, then the brim is too big for the sides and I have to gather it too. I am following the video precisely but cannot figure out what I’m doing wrong? I measured the pattern, it is printing at the correct size….I am lost. It should be so easy. I would love to know what I’m doing wrong!

I’m having the same problem. Did you figure it out?

I think I figured it out. It’s your printer settings. Mine was set on fill the page. I changed it to fit the page. I printed it again and it looks right now.

Sherry, did you figure it out? My husband printed it for me a few times. I’m not sure what he did to the settings, but we finally got it to print with the correct scale (the one inch measured correctly and all the pieces fit together). However, I just wasted so much time, fabric, and interfacing, because it 100% does not get anywhere near fitting when done this way. Like the above person posted, it’s inches too long. I’m so frustrated.

It’s all good now. I found the link. And I am so impressed by the professional work you’ve done! So neat to have all sizes at once. So easy to assemble!

im having a hard time figuring out how to download the free bucket hat pattern. I hit the download template & I end up in a site that has nothing to do with the pattern you have offered

Love this pattern! Is there a reason you could not cut out just two brim pieces, as a solid circle, rather than piecing 4 pieces together?

Thank you so much for the pattern! I want to make this for me!

Thank you, thank you ~ yesterday I decided to look for a bucket hat pattern and today you provided a perfect one with excellent instructions!

I would like to download the floppy hat pattern, but what I see is a download for winzip may times. Can’t I just pull up the pattern and print it. It’s so cute!

I’m trying to download it, if I try to sign up, it says the email is already in use. If I try to sign in, it doesn’t accept the password I use. There is no option to change the password which I guess is not what I thought it was. I tried the magic link thing and am getting nothing at my email. So how do I download it? I’d love to make one…. or several.

You must be a teacher! Amazingly easy to follow video tutorial! Thank you for this lovely pattern! I cannot wait to make my hat! Now, to dig through my material and see what I have to make it!
Thank you!

This hat looks awesome and I’m excited to make it!
Can you tell me where to find the adult size chart — I’m only seeing baby/toddler/young child. My husband was recently told to wear a floppy bucket hat while riding his yard tractor, to prevent sun exposure to a couple patches of pre-cancerous cells on his head. I’d like to make a masculine version of this for him!