How To Sew A Fedora Hat

Knowing how to sew a Fedora hat ensures that your hat will always be one of a kind. Additionally, once you have the skills and supplies, you will be able to make all the unique Fedora hats as you would like! Have one for every outfit. Are you curious as to how it is done? Below are the basics of how to sew a Fedora hat; furthermore, with time you will get more experience. Go wild!

Things you will need:

• Water
• Sand paper
• Felt material
• Spray lacquer
• Straw or felt hat
• Needle and thread
• Non-sticking spray
• Edge sander or large file
• Expandable, compressed foam
• Decorative ribbon or rope ( feet long)

1. Choose your Fedora hat block. Hat blocks are available on the cheap online if you’d like to skip this step; however, they are quite easy to make yourself if you would prefer. To make your own, you will need either felt or a plain, straw hat. Just grab one at your local thrift store. It does not matter what it looks like, you only need it for its shape.
 
2. Make the Fedora hat block. Use the spray lacquer on the inside of your felt or straw hat, allowing it to harden. This is not necessarily its permanent shape; you will have another chance to re-shape it, but make sure this is the shape you want it to have, as you will not be able to change the shape once it hardens. It should not take more than a few minutes to dry.
 
3. Make the Fedora hat block mold. Spray non-sticking spray, completely covering the inside of your Fedora hat. Use your expandable, compressed foam (can be bought from any hardware store). Fill up the hat halfway. It will take one full day to dry, but once dried, it will be the permanent hat block.
 
4. Sew on the decorations. This is the fun part. While your mold is drying, take this time to sew buttons, ribbons, rhinestones or any other bling you’d like to have on it. Decorate it with glitter, feathers or anything else you would like.
 
5. Smooth it out. Check the inside of the hat to see if the foam is dry. If it still feels tacky, continue to wait. Once dried, take the foam out; it should slide out easily. Use your sandpaper to smooth out any gaps or rough spots.
 
6. Make a ridge. Get out your edge sander. A very sharp file can be substituted, if need be. Make a ridge down at the bottom of the hat block, leaving about an inch to spare. The groove should be about half an inch wide. Carve it all around the bottom. The groove you carve is where you will place the rope, so it should be only slightly larger than the rope.
 
7. Cover the outside. Place the ribbon or rope inside the groove and let the remaining end of the rope dangle. The rope should be long enough to go completely around the inside, as well as around the outer side. Next, get the felt material covering and fit it over the hat block. Start at the top and work the material all the way down.
 
8. Sew it. For the final step, use the same colored thread as your material is; you don’t want it to be too noticeable. Use small stitches all around the outside of the bottom of the Fedora hat. Next, bring the dangling ribbon or rope up and around the outside of the bottom of the hat and make a jaunty little knot or bow. That’s all there is to it. You now know how to sew a Fedora hat to give out for gifts or just for your very own!

Tip:

If you are not happy with the shape, you can dampen a sponge and wipe the inside of the mold. It will become pliable again and you can then re-shape it. This should be done before covering the hat mold with your material.