Sew a Clown Hat to Match Your Clown Costume

  • 01 of 06


    Sew a Clown Hat
    Free Clown Hat Pattern to Sew. Debbie Colgrove, Licensed to

    A clown costume is not complete without a hat! The possibilities are endless once you have the basic hat constructed.

    Continue to 2 of 6 below.
  • 02 of 06

    Create the Pattern - Step 1

    Create the Pattern - Step 1
    Create the Pattern - Step 1. Debbie Colgrove, Licensed to
    • Decide on the height of the hat you want to make. (For this example I made a 12" high hat for a medium sized adult.)
    • On your pattern material/newspaper, starting at a straight edge, draw a half circle, the height distance from the center of the straight edge.
    • Cut out the half circle.
    Continue to 3 of 6 below.
  • 03 of 06

    Create the Pattern - Step 2

    Create the Clown Hat Pattern - Step 2
    Create the Clown Hat Pattern - Step 2. Debbie Colgrove, Licensed to
    • Form a cone from the half circle, and try the cone on the head.
    • Tighten the cone to fit the head.
    • Mark where the cone overlaps and add a 1/2" seam allowance.
    • Cut the pattern on the seam allowance line.
    Continue to 4 of 6 below.
  • 04 of 06

    Cut Out

    Cut Out and Seam
    Cut Out and Seam. Debbie Colgrove, Licensed to
    • Use your pattern to cut one of the fabric.
    • Cut one or two of the fusible interfacing depending on how stiff your interfacing makes your fabric. You want the fabric to be very stiff, similar to poster board stiffness.
    • Fuse the interfacing to the wrong side of the fabric.
    • Place right sides of the fabric together and sew a seam to join the sides.
    Continue to 5 of 6 below.
  • 05 of 06

    Turn and Bottom Finish

    Turn and Bottom Finish
    Turn and Bottom Finish. Debbie Colgrove, Licensed to
    • Press the seam to one side
    • Sew a seam finish to the seam allowance.
    • Turn the hat right side out.
    • Without flattening the hat, press the seam and hat by inserting the iron into the inside of the hat. Finger press or use a Wooden Seam Pressing Bar to press any seam that the iron can not reach.
    • Zigzag or serge the bottom raw edge.
    • Cut ​a strip of the costume ruffle fabric into 2-3" strips that are each two to three times the length of the bottom edge of the hat.
    • Apply a decorative edge as described in the clown costume directions.
    • Fold the fabric in half lengthwise and press the center fold.
    • Sew a gathering stitch down the center fold. (How to Gather Fabric)
    • Gather the fabric to fit the bottom of the hat, evenly distributing the gathers. This is done by marking the halfway mark around the edge of the hat and then half way to the mark so the hat is marked in quarters. Mark the ruffle fabric in fourths before gathering. Match the marks on the ruffle to the marks on the hat and gather the fabric as evenly as possible between the markings.
    • Refold the ruffle and hand sew the ruffle to the bottom of the hat, stitching the center of the ruffle to the edge of the hat.
    • Separate the layers of the ruffle to fluff the ruffle.
    • Sew fabric pompoms and sew them to the hat.
    Continue to 6 of 6 below.
  • 06 of 06

    The Elastic

    The Elastic
    The Elastic. Debbie Colgrove, Licensed to
    • Depending on the size of the head that will be wearing the hat, cut a piece of elastic about 12" long.
    • Attach the ends of the elastic to the sides of the hat. (Use hand sewing or a sewing machine bar tack.)
    • Try the hat on and tie the excess elastic so that it is comfortable under the chin.

    Note: If the hat is not stiff enough to stay upright, stuff it with stuffing or tissue.
    Want inexpensive clown hair? Save curled ribbon from gift wrappings and tape it to the bottom of the hat as clown hair. 

    Doll hair is also available in most craft stores. Sew doll hair to a fitted hat for clown hat below the hat.