Since I'm trying to make a few of these I thought I'd stop and take some pictures along the way. Hope this help someone take the plunge and start sewing. Though when all is said and done I wish the major manifactures would churn out a few billion of the suckers . Sewing this little stuff does give you an appreciation for those in HK/China working for the manifactures.
First you need a pattern. This is the one I use.
Print the pattern out full size and cut out your fabric. A little trick I use is to use a glue stick to lightly glue the pattern to the fabric. This will keep the pattern in place while you cut the pieces out.
You'll also need to cut out a slightly smaller version of the bill in thin cardstock. Now sew two of the crown pieces together along one side. Use nice small stitches and tie off the ends well. Repeat this with the four other crown pieces. The bill pieces need sewing allong the outside edge. The better you do your sticthing now the better the hat will look when it's finished. So take your time and take a break once and a while. I always find my stiches get bigger and bigger the longer I sew.
This is what you should now have.
Now for some fun, turning the bill rightside out. I use hairspry to stiffen my fabric to make it easier to cut and sew. To relax the fabric enough to turn the bill inside out I wet the bill with warm water until it nice and soft. Then use tweasers to tease the bill inside out. It takes a bit of poking and proding to get it into rough shape. Then insert the cardstock bill inside the fabic sleave to stiffen and further shape the bill. Put this away to dry nice and flat. Each of the pairs of crown pieces can be gently bent into shape dry. Just slowly bend them back on themselves until they lie flat.
Here's where we should be at now.
While the bill is drying. take two of the crown pairs and sew them together along one edge, much like you did before. The tricky bit is sewing the very top part of the hat where you run out of space to hold on to the darn thing. This is the trick I use.
By holding the hat with my pointed tweasers I can still drive the needle with my other hand.
Add the other pair of crown pieces and continue stitching until the crown of the hat is complete, but inside out. Pay particular attention to making good firm stitches at the top part of the hat because that part of the hat is under a lot of strain when you turn the hat inside out.
Next wet the crown of the hat with warm water and gently tease it inside out. While you do this shape the crown of the hat and turn up the bottom edge into a neat, even and straight edge. Grab the figure your going to use and put the wet, shaped crown on it.
Keep messing about until your happy with the look. Once the crown dries it will be pretty stiff and keep it's shape so now's the time to get it right. While the crown dries its a good idea to trim off any excess from the cardstock bill reinforcment. The cardstock should follow the edge of the fabric of the bill and is often just a little bit too big.
I'll leave this for a moment as I've got to finish taking pictures, I've been doing this while the crown dries, Be back soon with attaching the bill and finishing up. Once you get this far you're almost done.
If I haven't been clear please let me know as I'd like to get better at explaining things.
Hope this helps.