How to Make a Conductor Hat

Written by river lin
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You may need a conductor cap to finish off a Halloween costume or you may simply want one for fun. Because of the wide pleats that give the conductor's cap it's unique look, the band needs to fit snug around the head. Precise measurements are required. To make the conductor cap look more official, use blue and white striped duck fabric or heavy cotton. Instructions can make a child or adult-size cap.

Skill level:
Moderate

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Things you need

  • 2/3 yard heavy cotton or canvas
  • Medium to heavy weight interfacing
  • Newspaper
  • Pen or pencil
  • Ruler
  • Scissors
  • Fabric marker
  • Straight pins
  • Sewing machine
  • Iron and ironing board
  • Hand sewing needle

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Instructions

    Preparation

  1. 1

    Measure the wearer's head where the cap band should rest. Add one inch.

  2. 2

    Draw a rectangle on the newspaper to that measurement and 2 inches wide. Mark this as the inside band. Draw another rectangle the same length and 2 ½ inches wide. Mark this as the outside band.

  3. 3

    Measure the forehead across the eyebrows from the front of one temple to the front of the other temple. Draw a rectangle to this measurement and 5 inches wide. Mark this as the bill.

  4. 4

    Draw a 12-by-12 square on the newspaper. Cut the corners of the square to form an octagon with 5-inch sides. Mark this as the head piece.

  5. 5

    Cut out all the newspaper pattern pieces. Cut two of the corners from the bill so that one side is straight and the other is curved.

  6. 6

    Lay each of the pattern pieces out on the fabric and pin them in place. You should cut two bills from the fabric and one of each of the other pieces.

  7. 7

    Lay the outside band and the bill pattern pieces on the interfacing and cut one of each.

  8. 8

    Fuse the interfacing to the wrong side of the corresponding fabric pieces.

    Assembly

  1. 1

    Put the two bill pieces together, right sides facing each other, and pin in place. Machine stitch around the curved edge. Leave the straight edge open.

  2. 2

    Turn the bill right sides out. Use the end of a pen to push the fabric out against the seam. Press.

  3. 3

    Top stitch the curved edge of the bill. Top stitch again close to the first stitching.

  4. 4

    Attach the ends of the bands.

  5. 5

    Attach the bill to the inside band, right sides together, with a machine basting stitch.

  6. 6

    Press down the outside band all along one long edge. Pin the other long edge of the outside band to the straight edge of the bill. Sandwich the bill between the two bands. Machine stitch.

  7. 7

    Lay the octagonal piece on a flat surface to make the pleats. Pinch two corners of one flat side of the octagon and bring them to meet each other. Pin in place. Push the pinched fabric down flat to create folds at each side. Pin the two folds down in place. Repeat this step all around the cap at each side of the octagon. This will form a curve for the head. Machine baste close to the edges. Remove all pins.

  8. 8

    Align the front of one of the pleats with the centre of the outside band. Pin in place. Ease the rest of the cap into the circle of the band to pin the band to the head piece. Machine stitch.

  9. 9

    Hand stitch the inside band to the hat piece at the seam where the outside band is attached.

  10. 10

    Trim all loose threads.

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