Bucket Hat Sewing Tutorial: Insulated Winter Hat for Kids

A warm winter bucket hat for kids, sewn with the Vikisews Lila pattern. The video shows every step, including how to work with insulation, which is useful for any padded project.

Why make a winter bucket hat

A bucket hat is always on trend, and made in a waterproof fabric it's practical for rainy weather. It's a little tricky for a beginner, because the crown is round and the side panel has to be eased onto it evenly, but the video shows every step.

My tips for sewing an insulated hat

• Thinner insulation: the pattern is made for 200 g insulation, for very cold winters. For Portugal's climate I split my 100 g insulation in half to make 50 g, so I had to make the hat smaller. My first hat didn't work out, which is why there are two in the video.
• Cut the insulation with an extra 2 cm of seam allowance all round, because it moves while you quilt.
• Quilt the insulation to the main fabric with a 4–5 mm stitch, 8 mm from the edge. A Teflon or walking foot helps; guide the fabric with your fingers and pull it gently in opposite directions so it stays flat.
• Trim the insulation out of the seam allowances after quilting, to keep the seams thin.
• The brim facing is a little smaller than the brim, so it doesn't show on the right side: spread the ease evenly and understitch.
• Line the hat with cotton so it doesn't slip on the hair, and close the opening with small hidden stitches. My hat is thin, so I also topstitched the edges.

What you need for a bucket hat (size 54 cm)

• Vikisews Lila pattern
• Waterproof main fabric 50 cm
• Insulation 35 cm; I used 50 g
• Cotton lining 20 cm
• Teflon or walking foot optional, for the quilting; this snap-on Teflon foot fits most home sewing machines Find it ↗
• Janome 2030 DC sewing machine Find it ↗
• Singer Heavy Duty 4432 sewing machine Find it ↗
• Juki DDL-8700 industrial sewing machine I use it for outerwear in my atelier, for perfect stitches Find it ↗