542 Roll Brim Hat Made with a Woven Fabric

The other day a customer asked us if the 542 Roll Brim Hat Pattern could be made from a non-stretch fabric.  And, the answer is yes!  We looked at the pattern and how it was made and how it fit, and it seemed like it would be fine to make with a woven fabric.  But, we wanted to make sure, so I sewed up a hat with a thick woven poly/cotton blend and it worked perfectly!

If you are wanting to make this hat with a woven fabric, I would suggest using fabric with a tighter weave than the one I used.  The fabric I used had a bit of a loose weave which means it doesn't hold shape as well as a tighter weave.  The hat is designed for the brim to roll up so interfacing in the brim will be helpful for a woven fabric (especially if it is a drapier fabric) to give structure to the brim.  The button (one or more) on the side will also help keep the brim standing up and adds a nice decorative touch. Canvas, denim, and twill in cotton or wool are all good options to use for woven fabrics for this pattern. 

This pattern makes a hat that tends to finish on the larger side.  I would recommend making a muslin with a similar fabric to your main fabric (stretch or woven) to make sure it will fit how you want.  You may want to make it a size smaller than you think. 

The 542 Roll Brim Hat is a quick and easy project and only takes 1/2 yard of fabric!  You can make it from a wide variety of fabrics and with two brim styles and several options for finishing touches, you can make an endless number of hats with this pattern.