Balloon Cap Sewing Instructions

You can make it from an old pair of jeans to match the recycled jeans, or from corduroy or another fabric of your choice.

What you need 

  • Our pattern in your size 
  • Matching thread 
  • Scissors (for paper and fabric) 
  • Sewing machine 
  • Fabric (denim, corduroy, or cotton)
  • Band 
  • Pins

 Sewing instructions

Step 1

As a first step, cut out all the pattern pieces.

Step 2

Then transfer all the pattern pieces onto the fabric and cut them out.

Step 3

In the next step, the outer curve of the visor is turned right side out. To do this, place the two visor pattern pieces right sides together (that is, with the outer sides of the fabric facing each other). Then you can pin the seam or, if you are confident doing so without pins, simply sew around the curve using a presser-foot width seam allowance. Don't forget to sew a bartack at the beginning and end of the seam (sew briefly forward and then back).

Step 4

Sew the crown pieces of the hat in the same way. The only important thing here is to always leave approximately 1 cm open at the tip; this makes it much easier to assemble the individual pieces.

Step 5

Once the crown is finished, sew across the points from the inside to close the small hole that has formed.

Step 6

Next, turn the visor right side out and trim the corners. Ironing the visor can help here.

Step 7

Next, pin the visor to the center of the band, placing it between the two band pattern pieces, so to speak. Then close the pinned edge using a presser-foot width seam allowance. Make sure to stretch the band slightly and set the stitch a little shorter so that it remains elastic.

Step 8

Now sew the band to the crown. It is easiest to use a few pins to hold it in place. Make sure the crown is evenly distributed around the band and does not bunch up anywhere. Place the two pieces right sides together and sew them together using a presser-foot width seam allowance. Once the seam is finished, it makes sense to neaten the edge with a zigzag stitch.

Step 9

Turn the hat inside out, iron it if necessary, and trim any excess threads. Then put it on and explore the world!

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