When thinking of what I should make for one of my favorites series of the year, Andrea Pannell’s Handmade Costume series, my brainstorming list was all over the place. My boys want to be Hero Factory characters this year…uh…still not sure how or if I am going to pull that off. Then I thought about how it would be cool to share a pattern for Reid’s Ninjago Kai armor from last year. But…I am not really sure how many of you would be into that. ;)

In the end, I decided to keep things classic. And what could be more classic than a witch hat?

Today, I’m going to teach you how to make your own witch hat pattern in **any size**!

Let’s get to it.

MATERIALS

premium felt

matching thread & sewing machine, sewing essentials…

paper to make a pattern on (computer paper taped together or freezer paper works great)

pencil and chalk

calculator

ruler

measuring tape

paper and fabric scissors

Note: This requires a lot of math. If you hate math, don’t worry! I will walk you through it step by step.

MEASUREMENTS

First, measure your head around your forehead.

Add about 1/2 inch to 1 inch depending on how low you want your hat to sit on your forehead.

**This is your head circumference. **

*My head circumference is 23 1/4 inches (I added 1/2 inch).

Second, decide how wide you want the total width of your hat. **This is your brim diameter. **

*I made my brim diameter 19 inches.

CREATE BRIM PATTERN

To start, you need your **head diameter**.

You can determine this number using this formula:

*head diameter(pi) = head circumference*

In my case:

diameter (pi) = 23 1/4 inches

or 23.25/pi = 7 2/5 inches = head diameter

On pieced together computer paper or some freezer paper, draw out a circle with your desired brim diameter.

You may decide to figure out the brim circumference, but that won’t really matter for this hat.

From that brim circle, cut a hole out of the exact center, using your head diameter and head circumference measurement.

Tada! You have a brim pattern.

CREATE CONE PATTERN

First, decide how tall you want your hat. I decided to make mine 11.5 inches tall.

Then, determine the radius of your head measurement. To get this, you simply divide the head diameter in half.

radius = diameter/2

My head radius = 3.7 inches

*premium*felt, also sold by the bolt. You can see in the picture below how much thicker it is than craft felt.

Need more costume inspiration? Check out the other great costume tutorials being shared for Andrea Pannell’s Handmade Costume Series HERE.

Palak says

I love this– and I completely agree with you about the premium felt vs wool vs regular. I was surprised at the difference my last trip to Joanns!

Joanna Pabel says

I love it!

Anne Weaver says

This is an awesome tutorial!! And I'm totally geeking out on the geometry of a witch hat! I've got a Craft Gossip post scheduled for tomorrow morning that links to your tutorial:

http://sewing.craftgossip.com/tutorial-felt-witch-hat-make-it-any-size/2013/10/01/

–Anne

Rocky Lemuel Garcia says

Nicely done! This will be a good idea for this coming Halloween!

Erin A says

So great. This is going to be one of those tuts that everyone pins for future witch Halloweens. :)

AND, you killed it with Natalie's ensemble. That bleach trick on the hem…so genius. As soon as you mentioned the bleach I thought, "Oh yeah, bleach turns your blacks orange! Why didn't we all think of that before?"

Happy moving! Hope it's going as

mom23 says

Thank you for sharing this! Unfortunately I cannot handle this kind of math, even tho you clearly explained everything….I am totally math challenged! Maybe I can get my husband to caluculate for me and I'll stick with the sewing ;) I'm super impressed with your math skills, girl!!

britt schmiesing says

perfect. i love all of these cool halloween how tos that i am seeing lately. and this year seems to be the year of the witch so perfect!

Giulietta says

Thank you for sharing this tutorial! I'm not in love with math, but the hat is so cute that I'll try to do it ;)

Tracey K says

Thank you! I just made this hat, for myself, and it was very easy once I figured out the math. I added some felt roses (made from circles cut into spirals) all the way around, where the pointy top meets the brim. I might add a bow as well. In all I used under a half yard of the premium felt, including the roses. I think I will be a shabby chic witch this year, since that's what the hat brings

lemondedis says

what a great idea ! thank you so much ! i’ll make this for all the family (i’ll make one for the cat too – he’ll hate this but… ;) !) i shared the link here : http://www.pinterest.com/lemondedis/halloween-diy/

Justine says

I was wondering if you could tell me how wide you made the toddler hat brim and how tall? Thanks!

Delia says

Sure! The brim is about 4.25″ and the hat is like 9-9.5″ tall. I hope that helps!

Marlou says

Thanks so much for this! Very clear tutorial. I made a lovely wizard hat :D

Delia says

Thanks Marlou! I am so glad you enjoyed the tutorial!

D says

My 17 month old witch is all set for Halloween. Thanks so much for the tutorial!

Julie L says

Thank you! I made the perfect hat for my witch’s costume using this tutorial. The math is needed for the fit, and it wasn’t too “scary” to figure out.

I used a black jacquard fabric rather than felt. The cone is stiff enough to stand on its own. I cut two brims and sewed a stiff piece of interfacing between them. Finished it off with a ribbon of black roses around the seamline. Still a quick, easy sewing project.

And it looks great! Thanks again for the tutorial.

Delia says

Sounds gorgeous! I am so glad the tutorial came in handy!

Tiffany says

I LOVE this. Took me a while to do the math, but my Gandalf hat (for The Hobbit premiere) looks amazing. Thank you so much for putting thia up!!!

Delia says

oooh. That sounds cool! You’re welcome. Have fun!