How To Sew A DIY Lined Bucket Hat Without A Pattern (Spring & Summer Style)

A lightweight pastel floral bucket hat with a solid lining and delicate braid trim — a perfect handmade accessory for spring and summer.

How to Sew a Lightweight Lined Bucket Hat for Spring and Summer Without a Pattern

Dear Readers and Subscribers,

There’s something timeless and practical about a bucket hat. A bucket hat is so charming! 

It shields your face from the sun, adds personality to a simple outfit, and it’s lightweight enough to wear all spring and summer long. The best part? You don’t need a sewing pattern to make one.

Today, I’m showing you how to sew a fully lined DIY bucket hat from scratch — using lightweight cotton fabrics and even scraps for a beautiful, narrow 3/8" band detail that gives the illusion of a classic hat band.

This project is perfect for:

Using up stash fabrics

Mixing prints and solids

Creating giftable summer accessories

Adding a handmade touch to your warm-weather wardrobe

Let’s get started.

Why Sew Your Own Bucket Hat?

When you sew your own, you control:

Fabric weight (perfect for hot weather)

Print placement

Lining choice

Brim width

Decorative band detail

And because we’re not using a commercial pattern, you can customize the fit to your own head measurement.

Fabric Suggestions for Spring & Summer

Choose lightweight fabrics such as:

Quilting cotton

Cotton lawn

Chambray

Lightweight denim

Cotton blends

Linen blends

For lining, use lightweight cotton or even a contrasting print for a fun surprise inside.

Avoid heavy canvas for this version — we want breathable and easy to wear.

Supplies Needed

1/2 yard lightweight cotton (outer fabric)

1/2 yard lightweight cotton (lining)

Lightweight fusible interfacing (optional, for brim structure)

Thread

Measuring tape

Pins or clips

Iron

Sewing machine

Optional:

Scrap fabric for a 3/8" narrow band

3/8" narrow braid trim (alternative to fabric band)

Step 1: Measure Your Head

Use a measuring tape around the widest part of your head where the hat will sit.

Add 1/2" for ease.

This measurement will determine the length of the crown band.

Example:

If your head measures 22", cut your crown band at 22 1/2" long.

Step 2: Cut Your Pieces

You’ll cut:

Crown Top (Circle)

Cut 1 outer fabric circle

Cut 1 lining circle

(Approximately 7"–8" diameter for average adult — adjust if needed)

Crown Side Band (Rectangle)

Length = head measurement + 1/2"

Height = 3 1/2" to 4"

Cut:

1 outer

1 lining

Brim (Donut Shape)

Cut 2 outer brim pieces and 2 lining brim pieces.

Outer circle: approx. 13"–14" diameter

Inner circle: same size as crown top circle opening

Tip: If you don’t have a compass, use plates or bowls from your kitchen to trace circles.

Step 3: Assemble the Crown

Sew the short ends of the crown band right sides together to form a loop.

Attach the crown top circle to the loop.

Clip curves and press.

Repeat for lining.

Step 4: Sew the Brim

Sew the outer brim pieces together along the side seams if cut in half.

Repeat for lining.

Fuse interfacing to the outer brim if more structure is desired.

Place the outer brim and the lining brim right sides together and stitch around the outer edge.

Turn the right side out and press.

Topstitch around the brim in rows for a classic bucket hat look.

Step 5: Attach Brim to Crown

Attach brim to outer crown.

Attach lining crown to lining brim if constructed separately.

Place lining inside outer hat, wrong sides together.

Tuck raw edges under and stitch in the ditch or topstitch around the base of the crown to secure.

Press thoroughly.

The 3/8" Narrow Band Detail (The Special Touch)

This is what makes this bucket hat stand out.

Option 1: Scrap Fabric Band

Cut a 1 1/4" strip of scrap fabric.

Fold long edges inward.

Press.

Fold in half again to create a clean 3/8" finished band.

Wrap around the base of the crown.

Stitch in place.

This creates the illusion of a traditional hat band without bulk.

Option 2: Narrow Braid Trim

Instead of fabric, sew a 3/8" narrow braid around the base of the crown.

This works beautifully with:

Solid hats + contrasting braid

Print hats + neutral braid

Linen blends for a boutique look

This is where you can really personalize your design.

Style Ideas

Floral outer + solid lining

Solid chambray + bold scrap band

Striped outer + denim band

Neutral linen + braided trim

Bucket hats are the one accessory where you can have fun without overthinking it.

Why This Project Is Perfect for Scrap Sewing

You don’t need large yardage.

The narrow band detail is ideal for:

Fat quarter leftovers

Trim scraps

Vintage braid trims

Even denim scraps

If you’ve been holding onto small pieces thinking, “I’ll use this someday,” — this is the project.

Care & Wear

Lightweight cotton bucket hats are:

Washable

Packable

Foldable

Travel-friendly

They’re ideal for:

Gardening

Outdoor markets

Beach trips

Walking

Summer sewing days in the yard

There’s something satisfying about sewing a wearable accessory without opening a pattern envelope.

This DIY lined bucket hat is practical, creative, and entirely customizable — just the kind of project that keeps sewing joyful and useful.

And once you make one, you’ll likely make several.

You may even find yourself creating coordinating hats to match aprons, totes, or summer outfits.

Because when you sew, you’re not just making clothing.

You’re creating your own signature style.

Ready to Sew More?

If you enjoyed this DIY bucket hat project, you’ll love what’s waiting in my sewing shop. I regularly add sewing patterns, fabrics, trims, and helpful sewing notions to make your projects easier and more enjoyable.

Visit my Payhip shop to browse patterns, fabric finds, notions, and sewing inspiration.

And don’t forget to subscribe to The Designer’s Needle in the sidebar so you never miss new DIY tutorials, sewing ideas, and fresh creative inspiration delivered straight to your inbox.

Happy sewing — and thank you for being part of my creative community!