How to make a Mini Pirate Hat or Mini Tricorn Hat

Ahoy, makers! Are you ready to add a touch of pirate chic to your Halloween costumes? Our Mini Pirate Hat or Mini Tricorn Hat tutorial is exactly the treasure you’re looking for! Using our free pattern and tutorial, you’ll create a cute and fashionable mini hat that’s perfect for any pirate costume.

These mini hats are not only fun to wear but also easy to customize to the perfect size for you- from Large to Mini sizes! Give your pirate ensemble a fun, feminine twist with a mini hat that even Elizabeth Swann would love to wear! So, grab your materials and get ready to set sail on a crafting adventure to create the perfect mini pirate hat for your next costume party or event!

The Large Hat is approx. 3.75 inches high

The Medium hat is approx. 3 inches high

The Small Hat is approx 2.25 inches high

The Mini hat is approx 1.75 inches high

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Watch the Mini Pirate Hat or Tricorn Hat Video Tutorial:

Step-by-Step Guide: How to Make a Mini Pirate Hat or Mini Tricorn Hat

Step 1 – Cut Out the Mini Pirate Hat or Tricorn Hat Pattern Pieces

You can find instructions on how to assemble the pattern here.

You will need to print the pattern onto card stock as the pattern will become part of the hat.

Cut out the and assemble the  pattern – be sure to tape the front and the back of the pattern seams (where the paper overlaps) .

Trace the pattern onto the cloth using a marking pen (or even a regular pen – as long as it doesn’t bleed through the fabric.  

Be sure to trace the brim twice.  

Once on the solid line.  Then cut down to the dotted line and trace again.  Be sure to also trace the hole in the center.

Then cut down all the pattern pieces (the cardstock) to the dotted line.

Step 2 – Prepare All the Pieces for the Mini Pirate Hat

You now have four pieces of fabric cut out.  Set the smaller brim piece  aside. Spray the back side of the card stock with glue and center on each piece (there should be about an allowance all the way around – except for the hole in the center of the brim.  That should just line up with the fabric.

Using a glue gun, fold over the excess fabric and glue down along all the edges of the pieces. Leave the ends of the wall unglued.  The wall seam will appear less bulky if you don’t glue the ends under.

Step 3 – Assemble the Hat Wall for Your Hat

Taking the wall piece, gently fold it around so the two ends overlap (see note).  Glue ends together, be sure to hold it for a while to secure or use a clothes pin or clip to hold it in place.

Step 4 – Attach the Top of the Mini Pirate or Tricorn Hat

Once the wall is secure it’s time to add the top of the hat. Using your glue gun, glue around the the top part of the wall, just barley on the inside place top on glue hold in place to secure for a few seconds.

Step 5 – Build and Shape the Hat Brim

Glue cording along the edge of the brim, all the way around the hat (this will give the edge a nice finished look)  

Then glue the smaller brim piece onto the cardstock, taking car the glue the edges really well.

Step 6 – Attach the Hat Wall to Your Mini Pirate Hat

Place glue on the bottom of the wall of the hat (lining up the bottom circles) and press firmly onto the brim.  You may need to hold this for several seconds to ensure it is well glued.  You should be gluing the wall to the smaller brim piece that you just glued down.

For extra support tape a few pieces of tape between the brim and the wall of the hat.

Step 7 – Fold, Finish, and Style Your Halloween Hat

I strongly recommend that you play with the hat for a bit , before gluing the up the brim.  You’ll note that the brim is an oval.  The longer sides are designed to be the front and the back of the hat.  

Start with the “back” side, glue the brim of the hat to the wall.  Hold it for at least one minute and repeat two more times to make your hat.  Add a couple of clips or a comb to make it so it can stay in place.

You can glue them directly or use a scrap of fleece to glue them on, or you could also use a length of  elastic thread  and make it stay on the head like a party hat.  You now have a blank canvas to work with.

Now comes the fun part….

This for me is the best part! Add ribbon, tulle, beading, feathers, buttons, brooches, glitter, you name it and make this hat your own. I used tulle, feathers, ribbon and charms in the example. Old jewelry would work well too. Sky is the limit and your creativity reigns – what will your hat look like? Send me a picture (angel@fleecefun.com) or feel free to post it to the Fleece Fun Facebook page!

Some other ideas for this hat –

Trace the pattern onto scrapbook paper and make hats from paper for an even cheaper alternative.

Put together hat making “kits” for party guests to make their own mini top hat (great for pirate parties, birthday parties, girl’s night.)

The Mini size is so stinkin’ cute on little girls and babies – awesome for photos

Dress up a forgotten stuffed animal – and give an old toy new life.

Download the Free Mini Pirate Hat Pattern here.

You can get a free copy of Adobe reader here. By downloading  you are agreeing to pattern terms of use. Click the picture of the pattern envelope to download the .pdf !

OTHER COSTUME HAT PATTERNS: 

• Mini Top Hat Pattern
• Mini Witch Hat DIY
• Witch Hat Free Pattern 

MORE HARRY POTTER CRAFTS:

• How to Make a Wand
• Hedge Witch Hat
• Free Hogwarts Robe Pattern (kid to adult sizes)
• How to Make a Spell Book

MORE HALLOWEEN TUTORIALS:

• Boo Witch Mason Jars
• Candy Corn Bowling activity/ printable
• All Hallows Eve Printable Party Pack
• Fabric Pumpkin
• Jack O’Lantern Finger Puppet
• Halloween Printable Treat Box
• Jack O’Lantern Tote