The Making of a Custom Sun Hat

Written By Vivien Wise

My personal sun hat

A string under my chin!

In May 2023, I took my 5 panel cap pattern (that I use to make all the hats I sell) and made myself a sun hat from it. I wanted something with a big brim, that I could still fold up and put in a bag, and ideally washable. Oh and a string to go under my chin!

That summer, at a Pinewoods contra dance camp, a friend asked if I would make her a custom sun hat as well. I said yes, and nearly a year later, it happened! (Thanks Kathie!!)

I decided this would be a good time to describe the process of making a custom hat.

The hat is made of cotton fabric, and a foam liner in the brim (the kind you use in bag-making). The foam is stiff enough to fold upwards when you want to be able to see, but soft enough to fold up into my bag.

I love my sun hat!

  1. First, I found out her head size, and sent photos of some fabrics I had to see what she was most interested in.

  2. Then, I made some digital mock-ups of the hat with photo options, to give a better sense of it.

  3. Finally, I made the hat! We also decided on cord color.

So, here’s the final product! And this is all to say that you too, could order yourself a custom sun hat and get to design your own hat with me. You can find the listing here

Coming Up:

Come see me IRL sometime! (the titles link to more info)

Vivien Wise
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