July 15, 2024
How to make flat cap

How to make flat cap

A flat cap, also known as a driver cap or newsboy cap, is a classic and stylish headwear choice. Making your own flat cap allows you to customize it to your preferences. Here’s how to make a flat cap:

Materials You’ll Need:

  • Fabric for the cap (e.g., wool, tweed, cotton)
  • Lining fabric (optional)
  • Fusible interfacing (optional, for added structure)
  • Sewing machine
  • Thread
  • Scissors
  • Measuring tape
  • Ruler or pattern for a flat cap (commercial patterns are available)
  • Needle and pins
  • Button (for decoration, optional)
  • Cap brim (can be purchased or made from cardboard or plastic)


  1. Take Measurements:
    • Measure the circumference of your head where you want the cap to sit. This will be the band size of your cap.
    • Measure the distance from your forehead to the top of your head to determine the height of the crown.
    • Measure the distance from the back of your head to your forehead to determine the length of the brim.
  2. Create a Pattern:
    • Create a pattern for your cap based on the measurements you took. You can find commercial patterns for flat caps at fabric stores or use an existing cap as a reference.
    • The pattern typically consists of several pieces: the crown, the band, and the brim.
  3. Cut Fabric:
    • Lay your fabric flat and use the pattern to cut out the cap pieces. You’ll need one crown, one band, and one brim piece.
    • If desired, cut a lining piece using the same pattern.
  4. Apply Interfacing (Optional):
    • To add structure to your cap, apply fusible interfacing to the wrong side of the crown and band pieces. Follow the manufacturer’s instructions for fusing the interfacing.
  5. Sew the Crown:
    • Fold the crown piece in half, right sides together, matching the curved edges.
    • Sew along the curved edge using a 12-inch seam allowance, leaving the bottom edge open.
  6. Sew the Band:
    • Fold the band piece in half, right sides together, matching the short ends.
    • Sew along the short end to create a tube.
  7. Attach the Band to the Crown:
    • With right sides together, pin the open edge of the band to the bottom edge of the crown.
    • Sew the band to the crown with a 12-inch seam allowance.
  8. Create the Brim:
    • If you’re using a pre-made brim, simply attach it to the bottom edge of the band by sewing around the edge.
    • If you’re making your own brim, cut a piece of cardboard or plastic to match the brim’s shape and size. Cover it with fabric, and sew it to the band.
  9. Add Lining (Optional):
    • If you’re adding a lining to your cap for extra comfort and durability, sew the lining pieces together and attach them to the inside of the cap. Make sure to fold the lining’s bottom edge under to create a clean finish.
  10. Finish the Cap:
    • Fold the bottom edge of the band up to the inside of the cap to create a clean edge. Hand-sew it in place with small, discreet stitches.
  11. Add a Button (Optional):
    • Sew a button to the top of the cap for decoration.
  12. Try On and Adjust:
    • Try on the cap to ensure a proper fit. If it’s too loose, you can add elastic to the back band or make adjustments as needed.

Your homemade flat cap is now ready to wear. Enjoy your stylish and personalized headwear!