How to Make a Witch Hat (free pattern Child and adult Sizes)
Learn how to make a witch hat with this free pattern and step by step tutorial! With a few materials and this free pattern a couture style witch hat is within your reach! 
I’ve made two hats in very different styles to show you how can change up fabrics and decorations to make it look how you want. I designed this hat to more flattering than you’re average dollar store witch hat. The brim is shorter in the back to avoid bumping the back against yourself and the wider sides are more flattering to the face. With the wire i the brim it makes it easy to shape the hat how you want – making it a couture witch hat! If you’re going to be a witch you might as well be fabulous!
1 1/4 yard fabric for exterior. ( After making this hat from felt and from velour I recommend the velour since it has some stretch to it. A nice opaque fabric that has a little stretch to it will be easier to manage or fleece would work too)
1 1/4 yard of 1 sided fusible ultra stabilizer ( crafts and home decor stabilizer – look in the stabilizer section it’s very stiff and on a bolt only about 20 inches wide or just buy it here.)
2 yards of wide double fold bias tape in the color of your choice
2 yards of 10 gauge jewelry wire (this is the one I used)
1 non insulated butt connector for 10 gauge (like these)
Items to decorate your hat (floral, jewelry or wreath picks – whatever you want!)
Press cloth
sharpie pen
Sewing essentials ( sewing machine, pins, needles, thread)
Fleece Fun’s Free PDF pattern (available at the end of the post)
How to Make a Witch Hat Instructions:
How to Make a Witch Hat Instructions:
Step 1 – Cut out the elements to the witch hat
Decide which cone you want to use for the hat – there is a shorter cone or a taller cone that is designed to crinkle to the side.
Cut out 1 of the desired cone from the exterior fabric ( in the example the black felt)
On doubled fabric, cut two of the brim – be sure to cut to the exterior line and to cut out the center.
Tip: to cut out the center either snip the middle with scissors to cut going or use a rotary blade to make it easier.
Now it’s time to cut out the stiff interfacing. This interfacing is key to helping the hat keep it’s shape. Cut down the pattern so it’s the correct size for the interfacing. That’s the exterior of the cone and the interior circle of the hat.
The interfacing is a little more difficult to work with – and pinning the pattern to it is impossible. I recommend placing the pattern on it and tracing it with a sharpie. Then cut out the pattern. Cut one of the cut down cone.
Cut out 1 of the cut down brim. Note: for the brim the interfacing is the same size on the outside, it’s just the interior of the hat is a little different.
Step 2 – Add the interfacing to the top of the hat and brim
To give the hat a sturdy shape this interfacing is key. The first step is to iron on the interfacing.
Let’s start with the cone. Center the shape of the interfacing on the WRONG side of the exterior fabric ( since I’m using black felt this isn’t a big deal, but with most fabrics make sure that it’s the wrong side).
Using a pressing cloth and the correct settings on your iron (refer to the instructions that come with the interfacing – and make sure the glue is facing down so you do’t adhere it to your pressing cloth) iron the interfacing into place.
It should be nicely adhered and have space on the sides and bottom when you’re finished.
Repeat the step with the brim and on of the exterior pieces – adhere to the WRONG side of the fabric – there should be a space in the center where the exterior fabric can be seen. Note: the brim isn’t symmetrical – so make sure it lines up – if you’re having trouble try the other brim exterior piece and see if lines up.
Step 3 – Make the brim “SandWitch”
Time to bring the brim together!
Place the other exterior piece of the prim on top of the interfacing – so the RIGHT side is facing out. so now it should be Fabric, interfacing, fabric. The right side of the fabric should be facing out on the bottom and the top.
Locate the back of the brim (this is where the width is the smallest). This is where the bias tape should begin and end.
Sew the double fold bias tape around the brim (starting and ending in the back).
Be sure to leave a 3 inch section of the bias tape unfinished in the back for a space to insert the wire later.
Step 4 – Make the cone to the witch hat
Now it’s time to make the cone to the hat!
Fold the cone over so right sides are touching. Using a half inch seam allowance sew the cone together (I opted to use a zig zag stitch that caught the edges of the interfacing as I sewed to make it more sturdy.
Turn the cone right side out – take your time. It will be a little stiff and difficult but it will turn.
Be careful when pushing on the top point not to poke through it.
Step 5 – Bring the top and the brim together
Locate the back of the brim (where it’s the most narrow and line up the back seam of the cone with the back of the brim. Place the cone inside the the center of the brim
Slowly begin to pin the cone and brim together.
For this part you will want to pin it really well.
Using a half inch seam allowance* sew the brim to the top cone.
*Try your best to keep a half inch seam allowance – it’s ok if it’s not perfect. Lengthen the stitch a little and go slow. If you need to adjust make sure the needle is lowered in the fabric and adjust. Take your time it’s not a race!
Step 6 – Add the wire to the brim
Depending on the fabric you chose your brim might seem really floppy. Now it’s time to fix that.
Cut your wire so it’s the correct length (about two yards for threading will work).
Find your open gap in the bias tape and begin to thread the wire around the brim – be careful not to push so hard that the wire cuts through the fabric.
Continue to thread until it’s all the way though. Hook the ends of the wire around each other and make sure the the wire is evenly distributed around the brim and the brim can lay reasonably flat on the work surface.
Unhook the wires. Trim down one end.
place the butt connector on one end.
Crimp it into place.
Trim down the wire so it fits properly into the butt connector. Place it in the other side and crimp it into place, making a seamless loop.
Sew shut the opening in the Bias tape!
Step 7 – Decorate your witch hat
Now here’s the fun part!
If you made the taller cone it’s time to scrunch it down.
There are a couple of ways to do this. with a needle and thread thread through the top of the cone and sew it down, or fold it over and glue it down with a hot glue gun.
Now decorate it any way you want! I chose some items and hot glued them to the witch hat.
Download the Witch Hat Pdf Pattern by filling out the form below:
By downloading you are agreeing to pattern terms of use. Click here to go to the download form.
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