Tutorial: Scrap Denim Bucket Hat
Learn how to make an upcycled bucket hat using scraps of denim. The free pattern (below) was made with small pattern pieces so that you can easily cut up old pairs of jeans to patch together different shades and tones of the denim for a creative and sustainably made hat.
Note: when sewing with denim, I recommend using a heavy weight or jeans needle with your sewing machine. A standard needle may snap if you try to sew through too many layers of denim.
Supplies Needed:
(all of my patterns include 1/2″ seam allowance)
Step 1
Cut out your pattern pieces from old jeans
You can use multiple pairs of old pants or just scraps of denim or other medium-heavy weight fabric.
You can use a lining fabric for the inner side of the hat, or cut the lining out of denim as well.
Step 2
apply buckram or interfacing
Apply buckram to one 1 top piece, 4 crown pieces, and 4 brim pieces. A heavy weight interfacing can also work.
Step 3
sew the crown together into a loop
with right sides together, sew the 4 crown pieces to form the hat.
Step 4
sew the top to the crown
With right sides together, sew on the top of the hat. The press the seam for a neater finish.
Step 5
Sew the brim together into a loop
With right sides together, sew the 4 brim pieces
Step 6
Repeat the previous step with the lining brim layers
Step 7
Sew the brim and brim lining together
With right sides together sew the brim to the lining along the outer edge.
Step 8
Turn the brim to the right side
Clip and trim the seam, then turn the brim to the right side through the center.
Step 9
press and baste
Press the brim and topstitch along the outer edge of the brim. Then baste the inner edges of fabric together
Step 10
sew the brim to the hat
With right sides together, sew the brim around the hat.
Step 11
sew the crown lining
Repeat step 3 with the lining for the crown to sew it into a loop.
Step 12
Sew the top to the lining
Repeat step 4 and sew the top to the crown lining.
Step 13
Place the hat with the brim inside the lining and sew around the edge
The brim will be sandwiched between the hat and lining layers. Leave a gap so that you can turn it in the next step.
Step 14
turn the hat to the right side and sew up the gap
Flip the hat through the gap in the lining, then fold over the lining and hand-sew it in place.
Finished!
