How to Make a Mini Top Hat (free pattern or template)

Learn How to Make a Mini Top Hat with this free pattern and template.  This fabulous mini hat comes in 3 mini sizes for you to make it in just the size.  Perfect for Halloween costumes or a dress up fascinator this hat for comes to life when you decorate it to suit your style.  With a few materials you can make this mini top hat that will be a costume box staple.  

This DIY includes two versions of the hat the “classic” version that has a rounder shape and the newer version that is more elongated and has a moldable brim.  For reference I am wearing a medium sizes hat.

This pattern has been updated, I’ve kept the “classic” version below that is a little more simple than this one – but I love the new shape and bendable brim that the new pattern offers.

The Large Hat is approx. 5.75 inches high and 8.5 inches at the brim
The Medium hat is approx. 4.5 inches high and 6.5 at the brim
The Small hat is approx.3.5 inches high and 4.5 wide at the the brim.

This DIY includes two versions of the hat the “classic” version that has a rounder shape and the newer version that is more elongated and has a moldable brim.  For reference I am wearing a medium sizes hat.

How to Make a Mini Top Hat (free pattern or template) Instructions:

Step 1 – Cut out the Free Pattern Pieces

Decide on the size of hat that you’re making and assemble and cut out that pattern.  To start we’ll cut out the cloth pieces.

Notice that there are two lines on the pattern.  We’ll be cutting to the solid line.

Cut 1 of the bottom seal, and top.  Cut 2 of the mini top hat brim.

Cut 1 of the Mini top hat wall.

These are all of the fabric pieces you need.

Cut down the pattern to the dotted line.

From the 1 sided stabilizer trace and cut out the wall and hat top.  From the 2 sided stabilizer cut out 1 of the brim.

Or you can trace the pieces onto poster board or a cereal box and use this for stabilizer – just be aware that you can’t sew any of the pieces if you use cardboard.

You’ll need 1 wall, 1 brim and 1 top.  

These are all the pieces you need to make a single hat.

Step 2 – Prep the top hat pieces for Assembly

If using the poster board, spray the pieces with adhesive spray (outside in a well ventilated area) and adhere to the pieces.  Center them on the fabric as best you can so there is an even line of fabric around them.  Sandwich the poster board between the two brim pieces.

For the stabilizer center it on each of the pieces and iron on, following the instructions on the stabilizer. Make sure the adhesive side ( the bumpy side with the glue is touching the fabric).  Do this with the wall.

The mini hat top.

With the brim we’ll use the 2 sided stabilizer (meaning it has glue on both sides).  Sandwich it in between the two brim pieces.

Iron it into place.

Step 3 – Begin to assemble the hat

For the sew version: Take the wall and bend in half, right sides touching. Zig sag stich together along the edge of the stabilizer.  If you’re not sewing:  Fold the hat the opposite way – so the wrong sides are touching, fold the ends (the flaps of fabric on the ends not touching poster board) in and glue them together to form the back seam of the hat.

Once sewn flip the hat right side out.

Whether you’ve sewn or glued it this is how the wall should look.

Step 4 – Make the Brim

If you’re using poster board, simple glue the double fold bias tape to the edge of the brim to finish it.  It you use the stabilizer it get’s more interesting.

To give the hat more personality we’re going to make the brim moldable.  To do this we need to add the wire.

On the what you want to be the bottom of the brim sew on the single fold bias tape, all the way around.

Use you’re edging foot and line up the edge of the unfolded bias tape with the edge of the brim and sew using a straight stitch.

Once you’re done that you need to pull the non sewn edge of the bias tape over so it now sits on the top of the mini top hat brim.

Sew down along the edge leaving a 1 – 2 inch gap for inserting the wire towards the back of the hat.

This will make the channel for the wire to thread through.

It also give a nice rim to the hat brim.

Take the wire and roughly measure around the brim for the length you need and cut.  Tip: it’s better in this case to have it be too long than too short.

Thread the wire around the brim.  Take your time, be gentle.  Make sure the head doesn’t get snagged on the fabric and keeps moving.  Thread until it reaches the other side.

Grab the butt connector.

Add it to each end, trimming down the wire so it will fit.

Top stitch the gap shut.

Step 5 – Bring the Mini Top hat together

Now it’s time to bring this fabulous fascinator together.

From here on out it’s all about the glue gun.

Let’ start with the top of the hat.  Take the hat wall and the hat top.

Glue the excess fabric around the edge to the stabilizer for the top of the hat.

Do this with the just the top of the wall as well.

With those pieces prepped glue the top of the hat to the wall.

Have the seam line up with the top of the oval ( so the seam will be in the back).  Glue the edges together, take you’re time.

Now it’s time to add the brim.  Place the top and wall so they are sitting upside down.

Place the brim on the wall.  The bottom of the brim should be facing up at you.  The excess fabric (the stuff with out stabilizer)  pulls through to the other underside of the brim. 

Glue this fabric to the underside of the brim. It will make a little oval around where the wall and brim meet.

Once the hot glue is set, shape the brim as you desire.  I recommend doing this before decorating the hat.

Step 6 – Decorate your Mini Hat and Make it wearable.

I find it’s easier to decorate the hat before adding the headband or combs.  So now it’s the fun part decorate your hat with all the trimmings.

Tip; keep a lint roller hand to clean off your hat.

Now it’s time to make your hat wearable!

Take the bottom seal piece and glue it to a head band slightly off center.

Then glue to the bottom of the hat.  Or..

You can glue a comb to the bottom.  Or…

A couple of clips is another option.

That’s it!  The Mini Top Hat is finished.

Fill out the form below to get the free pattern:

By downloading  you are agreeing to pattern terms of use.

More Great Costume Patterns:

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Mini Top Hat Pattern Classic Version Instructions:

This mini top hat free pattern and tutorial uses a template to make this accessory possible.  Cute and chic, these mini top hats are all the rage. Whether you’re into Steampunk, Burlesque or classic Victorian this Mini Top Hat is the crowning piece to your costume. Make the perfect mini top hat in the perfect size that you want. Sew and No sew options available.

The Large Hat is approx. 5.75 inches high and 8.5 inches at the brim
The Medium hat is approx. 4.5 inches high and 6.5 at the brim
The Small hat is approx.3.5 inches high and 4.5 wide at the the brim
The Mini Hat is approx. 3 inches high and 4 inches wide at the brim
Materials you will need:
1/4 yard polar fleece or felt
Items to decorate you hat (feathers, ribbon, tulle, brooches)
Barrette Clips or combs
Hot glue gun
thread (for sew option)
spray on adhesive (for no sew option)
The .pdf pattern printed on card-stock.

Sewing Essentials (if sewing)

Video tutorial here, written below:

No sew version of the hat

No sew will work for all the hats sizes.  However, it works best for the small and mini sizes of hat.

1- Cut out the Pattern

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; one with a hole in the center and one without.

Then cut down all the pattern pieces to the dotted line.

2 – Prep all the pieces

You now have four pieces of fabric cut out.  set the brim piece that does not have a hole in the center aside.

Spray the back side of the card stock with glue and center on each piece (there should be about a.5 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 with the exception of the brim pieces.

Note:  I did this differently in the example – but trust me it will look better if you do it later – I’ll tell you when.

3 – Assemble the wall

Taking the wall piece, gently fold it around so the two ends barely over lap.  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.

4 – Add the top of the 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.

5 – Add the first piece of the brim.

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.
Tip:  Place the seam where you will adding all your feathers and tulle – that way it can be covered.  In my example I placed the seam slightly to the right of the  of the front.  The brim is an oval shape – the sides should be the thinest part of the oval and the brim should be wider at the front and back of the hat.

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

6 – Finish Assembling the Hat

Using your glue gun, place glue on the brim card board and place remaing piece of the brim on it, sealing off the hat.  Then Using glue all along the edge of the brim fold over .5 excess of cloth to finish  off.

Note:  Excess is already folded over in the example in the picture, but it will make a nicer edge if you do it this way.

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. You could also  use a length of  elastic thread  and make it stay on the head like a party hat.

Now comes the fun part….

7 – Add some personality

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 a button in the example. Old jewelry would work well too. Sky is the limit and your creativity reigns – what will your hat look like? 

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 New years Eve parties, birthday parties, girl’s night.)

Sew Version of the hat (best for medium and large)
1- Cut out the pattern.

If the thought of using a glue gun for everything makes you cringe here is a sew option for you.  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 with a hole in the center.

Then cut down all the card stock  pattern pieces to the dotted line.

Note: to make the hat extra sturdy you may want to consider gluing the carstock to poster board and cutting out the poster board wit the card stock.  The card stock with teh posterboard will make for a much sturdier hat.

2 – Begin to sew

With right sides together pin fold the wall in half and pin ends.

Sew ends together using a .5 seam allowance. trim down seam

3 – Add the Top

With right side facing down (right sides together) pin the top on to the top of the wall ( the wider end).  sew together using a .5 seam allowance then trim down the seam.
Set aside.

4 – Sew the brim

With rights sides together sew the outer edge of the brim together using a .5 seam allowance. Trim down the seam after finished to eliminate bumps.

5 – Sew the Brim to the rest of the hat

With right sides together pin ONE side of the brim to the wall of the hat (see picture). Sew together using a .5 seam allowance.  Trim down the seam after finished to eliminate bumps.

Tip:  Place the seam of the wall where you are planning on adding your decorations.  This will allow the seam to be covered.
Note:  The reason you sew on one side of the brim is to allow you to insert card board into the brim later.

6- Insert the hat form.

Piece by piece insert the hat form starting with the top of the hat.  you will need to bend each piece a little when inserting, this is why card stock and poster board works but a harder cardboard would not.

Roll up the wall and insert it into the hat.  Line up the seam of the wall with the seam of the hat.  Tape the cardstock seam in place and tape the wall to the top.

Flip brim right side out and carefully work in the brim piece (you may need to cut a couple of small slits in the under brim to get this to work.

On brim form is in place tape it to the wall.

Now decorate your hat!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 a button 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!