Chef's hat sewing tutorial

Chef's Hat tutorial by hungryhippie:

I used Kona cotton in white.

The first two times I used interfacing to stiffen the fabric, but the third time I did not. It didn't make a noticeable difference-- so I recommend no interfacing.  Let's keep it simple, shall we?  


Cut your pieces:

Fold the rectangle piece in half lengthwise and press.

Sew the free edge, leaving the short edges open.

Press the stitches to set them, then flip the tube right side out.  (RSO)

Fold over the short rough edge 1/2 inch.  Then fold again another 1/4 inch to encase the edges. Press, then stitch. (See the next three photos.)

Do both short edges like this.

Now measure up the Velcro pieces and make sure they are the same length as the rectangle tube.  We will attach one piece to one end, then flip it over and attach the other piece to the opposite end. Pin and try your placements out before sewing them down. (!!)  

Sew the Velcro in place, I use a very small stitch 3mm.

In this photo the ends are flipped---be sure your Velcro is placed so when the tube is in place it will secure. 

Test placement out.

Set the tube aside for now. 
Let's handle the circle bit.

You've already cut your circle piece out:

Sew two rows of basting stitches for gathering (or use your serger to gather/ruffle) the edge, 1/2" in from the outer edge. 

If you need help with gathering, try my short tutorial here.   

I'm pointing to the area to sew the long stitches, so at least 1/2" in from the edge. 

Gathering// Pulling the threads little by little.


Match RST the rectangle and the circle piece, pinning as you go. Remember, RST (right sides togeher). Pin liberally.  

 * You might need to gather more or less as you match the edges of the circle and rectangle. I started from the middle and worked my way out in each direction gradually...

At first, it seems like a hot mess. It comes together little by little. Hang in there.

Sew a basting stitch first, and check the seam.

Then go over the seam again either with a serger or a sewing machine zig zag stitch. 

Once sewn, pink the edges if you are not serging.

Pinking shears to the edges if you didn't serge, to prevent fraying.
This way it will be machine washable & dry-able.

Turn RSO (right sides out) and press the seam allowance. Top stitch to make it look nice and neat.

Be sure to catch the seam allowance, pressing it beforehand to one side. ;)

Trim all threads, poof it out with your hands, make sure all seams are neat and tidy.

Pop it on your little one and get ready to bake! 

 Side view

Back view

 Even the deer loves the hat. :)

This is make #2 in which I placed the Velcro horizontally rather than vertically. Do your thang! Make it work for you.

We are off to make scones. MMmmmmm.

If you have any issues, please email me! hungryhippie (at) live.com

Peace out lovers!

I did not teach her this.

Sharing at:


  1. What a fun project. The little girl models make it that much more fun to look at. Love it.

  2. Love love love the chef's hat instructions...my three kid-chefs are now grown, but middle child needs a chef's hat for sure...while she's working towards a PhD in International Education, she does part-time cake decorating!


I appreciate every comment, thanks so much for taking the time. It means A LOT to me. :)