Tutorial for "The Hummingbird" scrub hat with elastic

Here are step by step directions that should  help you to sew your own  Hummingbird scrub hat with elastic. This hat is composed of two pieces. The long narrow piece is what I refer to as the "Front piece B". The large circular piece is what I refer to as the "Top Piece A".

First download the pattern and print it off.
click here to download the pattern

Tape the pages together as directed on the pattern pages.
Cut the pattern out on the heavy solid lines.


Step 1: Place pattern pieces onto fabric pieces as directed and cut out.
Step 2: Follow directions as on "Top piece A" pattern piece by folding edge over 1/4" and pressing with an iron.
Step 3: Double fold this over another 1/4" and press again with an iron.
Step 4: Now stitch these folds down stitching close to the edge (seen in picture below)

Step 5: Fold the bottom edge of  piece "Front piece B" up 1/4" and press with an iron. Now double fold this up another 3/4" and press. Do not sew this down at this time. Next unfold again, Make a line 3 1/2" in from the edge (I use a fabric marking pen that erases with water).

Place elastic on fabric overlapping the line a little

Flip fabric back up on the fold as seen above.

Using a zig zag stitch sew at the marked line as seen above. I went forwards and then backwards again to make it very durable. I want this elastic to stay put.

Place the "Front piece B" and the "Top piece A" together. THE RIGHT SIDES OF THE FABRIC NEED TO BE FACING EACH OTHER. (wrong side facing you) The "Front piece B" should be on top. Place several pins to hold in place. You may need to pull on the "Front piece B" a little to ease it around the circular shape of the top piece. The fabric has a little give and stretch to it so this is not difficult to do.  Now stitch the two pieces together using a straight stitch and a 1/4" seam allowance, removing the pins as you go. Go back now and zig zag stitch the edge to prevent fraying. (Or if you are lucky enough to have a serger just serge the two pieces together)

Step 9: Repeat steps 6 and 7 but on the other side.  (note I do not have a picture of this). At this point the bottom edge of "Front piece B" is connected by the elastic. The "tail" of "Top piece A" is still flapping loose.

Step 10: Sew all the way around the bottom edge of the hat close to the edge.

Step 11: Now it is time to create the brim. Flip the bottom edge up towards the front of the hat. I like to give it a press with the iron at this point. Now top stitch down in place close to the edge.

 Step 12:  Time to work on the bottom edge of "Top piece A" First iron this edge up 1/4". Then fold up another 3/4" and iron again. (This is exactly how you ironed the bottom edge of  "Front piece B" in step 5) Time to sew the little flap at the bottom of "Top piece A" with the elastic encased in it. You really need to pull on the elastic to stretch in out so that you can get it in the machine to sew it.

 Note: When I sewed this hat I did step 12 before I did step 11. It does work but you have to work the elastic a little to flip it because it is already encased in the middle portion. I realized later it would make more sense to do it in the order I described.

Now you are finished. Try on the hat. How does it feel? If it feels a little bit loose go to one of the openings at the back, pull on the elastic. Pinch it together until it feels like a good fit. Remove hat while keeping your fingers pinched on the elastic. Look how much elastic is in your pinched fingers. Put the elastic in the sewing machine and sew it in a little. Try it on again. Hopefully you have achieved the perfect fit.  Remember, you do not want it to fit too tight. I have made this mistake a couple of times and I just get headaches from wearing a hat that is too tight.