Measurements you need
Tape around the head: in front above the eyebrows across the forehead, at the back along the most prominent part of the back of the head. Don't pull tight.Tape around the head: in front above the eyebrows across the forehead, at the back along the most prominent part of the back of the head. Don't pull tight.
Usually 21¼–22⅞ in for adults.Usually 54–58 cm for adults.At the side of the head: from the line above the eyebrows (where you took the head circumference) up to the crown. You can leave 0 — we'll estimate from the head circumference.At the side of the head: from the line above the eyebrows (where you took the head circumference) up to the crown. You can leave 0 — we'll estimate from the head circumference.
Usually 7⅛–9 in for adults.Usually 18–23 cm for adults.How the hat is drafted
The width of each panel at the hem is the head circumference multiplied by the fabric stretch factor and divided by the number of panels. The sides of the panel are straight, with a curve at the top toward the point; the angle at the point is set so all panels meet at the crown without a pucker. For a two-half hat, the top is a gentle dome and the seam over the crown is smooth, with no "horn." The height of the piece is the hat depth with a small correction for stretch in the height, plus the cuff.
The pattern maker checks the draft itself: the circumference at the hem, the height, matching seam lengths, the panels meeting at the crown, and the cuff length. The results appear in the "Draft check" section.
How to sew
Sew the panels in pairs, then join the pairs together — the points should meet at a single point. Sew with an overlocker or a stretch stitch. Fold the cuff outward twice and secure along the seam; fold the band into a ring, in half by height, and sew it to the hem, stretching as you go.
How to print and tape
Download the PDF on Letter or A4 sheets and print at 100% scale, without "fit to page." The first sheet has the test square: measure it with a ruler. The sheets are taped together with an overlap along the strips ⅜ in1 cm; the sheet numbers and assembly diagram are on the first page. For a copy shop or plotter, choose "One-sheet PDF."
What you get
A hat panel or half in full size, with the cuff fold line; a cuff band if you need one. Grainline, overlock seam allowances. The pattern fits on two or three Letter or A4 sheets.
FAQ
Which cut should I choose?
With 6 panels, the hat sits as an even dome and the seams meet at the crown. With 4 panels it's a little simpler, and the hat is slightly roomier right at the crown. With two halves it's the easiest to sew (two side seams and a seam over the crown from ear to ear), but this hat doesn't hug the dome of the head: at the crown it's noticeably roomier and sits a bit like a "cap."
Why is the hat smaller than the head circumference?
Knit fabric stretches, and the hat stays on the head thanks to that stretch. The circumference at the hem is the head circumference multiplied by a factor: 0.9 for low-stretch fabric, 0.85 for medium, 0.8 for rib knit and fabric with lycra. Stretch 3⅞ in10 cm of fabric across: up to 5⅛ in13 cm is low, 13–16 is medium, more is high.
Cuff or band?
The cuff is a continuation of the hat itself: the piece is longer by twice the cuff height, and the hem is folded outward twice. The band is a separate ring of rib knit: it's sewn to the hem of the hat, stretching slightly. Without a cuff, the hem is simply folded up.
How do I make the hat double-layered?
Turn on "Double (with lining)": all panels are cut again from lining knit — fleece, jersey. Sew two hats separately, place one inside the other wrong sides together, and join them at the hem.