How to Make a Simple Billed Cap

I love making hats if you haven’t figured that out yet.  I decided I wanted to make a hat with a bill so I modified one of my other patterns and added a bill to it and it came out perfect.  This simple billed cap is just that, simple.  It may seem complicated but it really isn’t.  It is fully lined and just really cute.  I modified my sun hat pattern to create this one.  Instead of a full brim I decided to make it about a quarter of the size.  This allows for me to men the small bill at the front of the cap.  It is similar to a baseball cap but not exactly as you can see.  

I used a nice quilting cotton for the outer fabric for my cap and a Kona cotton for the lining.  Both were purchased at JOANN Fabric & Craft Stores.  I added some Pellon Peltex to the bill to keep it stiff that I also purchased at JOANN Fabric & Craft Stores.  You can get all of these items at Hobby Lobby, Fabric.com or onlinefabricstore.net.  Otherwise that is all that is necessary to make this fun little billed craft.  This post contains affiliate links that if you click on them and make a purchase I may receive a small commission at no extra cost to you. As an Amazon Associate I earn from qualifying purchases.

If you would like a video tutorial of this project head over to YouTube and check out my video.  While you are there subscribe to my free YouTube channel.  

What you will Need: How to Make a Simple Billed Cap

• Pattern Pieces from the Sun Hat Pattern you can get by clicking on this link
• Pattern for the Bill you can get by clicking on this link
• 1/2 yd outer fabric
• 1/2 yd lining fabric
• 1/8 yd Pellon Peltex or other heavy weight interfacing
• 1/2 yd Pellon 808 interfacing
• One covered button for the top

Step 1: Cut out the Pieces

Take the triangular pieces from the sun hat pattern and cut 6 each of the outer fabric, lining fabric and Pellon 808.  Cut 2 of the bill pieces from the outer fabric. Cut one piece of Peltex from the bill pattern. Remove the 3/8″ seam allowance from the interfacing piece.

Step 2: Fuse the Interfacing

Fuse the Pellon 808 to the outer triangle pieces following the manufacturer’s instructions.  Fuse the Peltex piece to one of the outer bill pieces also following the manufacturer’s instructions.  

Step 3: Stitch the Crown

Place two outer triangle pieces right sides together and stitch using a 1/2″ seam allowance.  Add a third triangle piece and stitch.  Stitch the three additional outer pieces in the same way.  Topstitch on both sides of each seam.  Place the two pieces of three right sides together and stitch across the top joining them.  Topstitch along the seams as before.  Repeat for the lining triangles except you do not need to topstitch and you should leave an opening in one of the triangle sides for turning in a later step.

Step 4: Create the Bill

With right sides together stitch the two bill pieces together along the curved outer edge leaving the inner edge open and using a 3/8″ seam allowance.

Step 5: Stitch the Pieces Together

Place the bill piece together with the outer piece and clip or pin.  Baste the bill to the outer piece to secure it.  Insert the outer piece into the lining piece so that the bill is in between the two layers and clip or pin all the way around.  I prefer wonder clips for this because of the bulk.  You can purchase wonder clips here. Stitch all the way around the cap.

Step 6: Turn the Cap

Reach into the opening you left in the lining of the cap and turn the cap right sides out.  Stitch the opening closed using ladder stitch.  If you are unfamiliar with ladder stitch check out this video.  Press.

Step 7: Add the Button

Cover a coverable button following the manufacturer’s instructions and stitch it to the top of the cap through the lining to prevent the lining from sagging.  You have now finished your simple billed cap.  

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