As a sewing enthusiast, I am continually on the hunt for unusual clothing or accessory items that I may create at home. A homemade zipper hat is one such pattern. If you are unfamiliar with the zipper hat, it looks very similar to a prisoner’s hat but it has a brim. The zipper is inserted in the middle of the straight sides. When the two side pieces are separated from the zipper, the top of the hat becomes a prisoner’s hat. Make your own zipper hat from a single piece of fabric or from several pieces of scrap fabric.
The pattern requires two 8-inch squares of fabric, two strips of fabric 2 1/2-inches wide by 25-inches long, two pieces of fabric 4-by-9-inches, one 4-by-9-inch piece of iron-on interfacing and a 24-inch separating zipper.
Step 1 – Draw an 8-inch circle on a piece of paper using a compass. Cut the circle from the paper.
Step 2 – Fold the fabric to create a section of fabric that is 9-inches wide. Place the paper circle on the fabric and pin through both layers of fabric. Cut through both layers of fabric to create two 8-inch circles.
Step 3 – Measure and cut two strips of fabric 2 1/2-inches wide and 25-inches long.
Step 4 – Create the brim. Measure and cut a piece of paper into a 4-by-9-inch rectangle. Match the two 4-inch ends. Crease along the fold line. Mark the center of the fold line. Place the folded rectangle on a flat work surface so the fold line is on the right.
Fold the paper circle in half. Turn the circle so the fold line is on the right. Place the folded circle on the folded rectangle. Line the top edge of the folded circle with the mark on the folded rectangle. Trace along the top edge of the circle. This creates the bottom edge of the brim.
Connect the top of the fold line on the rectangle with the outer point of the curve created by tracing along the edge of the circle. The curved line should match the curve of the circle. Cut the completed brim from the paper rectangle.
Step 5 – Iron a 4-by-9-inch piece of iron-on interfacing to the back of one piece of 4-by-9-inch fabric.
Step 6 – Place the two 4-by-9-inch pieces of fabric on top of one another so the right side of the fabric is on the inside. Place the paper brim on the fabric. Pin in it place. Cut through both layers of fabric to create the brim.
Step 7 – Pin the brim together along the second curved line drawn in Step 4. Sew a 1/2-inch seam along the edge. Remove the pins, turn and iron.
Step 8 – Match the two circles together so the right sides of the fabric are facing out. Place a pin in the center of the circles to hold them together.
Step 9 – Fold a 2 1/2-inch strip in half so the right sides are on the inside. Match the two short ends. Sew a 1/2-inch seam. Repeat the process with the second strip.
Step 10 – Create a 1/2-inch fold on one edge of the sewn strip to create a clean finished edge. Pin and press. Remove the pins. Repeat the process on both edges of the second strip. A clean finished edge means to fold one cut edge to the back of the fabric and iron in place.
Step 11 – Match the edges the circle and the right side of the fabric of one 1 1/2-inch strip and pin in place. Sew a 1/2-inch seam to connect the first side to the top of the hat.
Step 12 – Pin the separating zipper to the bottom edge of the strip connected to the top of the hat and to the clean finished edge on the second strip. Sew the zipper in place.
Step 13 – Pin the cut edge of the sewn brim on the bottom edge of the hat. Sew into place with a 1/2-inch seam. Continue to sew a 1/2-inch seam along the bottom edge of the hat to create a straight edge. It does not matter where the brim is placed along the bottom edge of the hat. Think about where you would like the zipper pull. I placed mine on the left side just above my ear.
Tip: Change up the pattern and sew the zipper and brim in place before attaching the straight sides to the circle.