Okay, so today I’m gonna share my experience making a trendy baseball cap. It was a fun little project, and I learned a few things along the way.

First off, I started by gathering my materials. I had some denim scraps lying around from an old jeans project, so I figured that would be perfect for the cap. I also grabbed some interfacing to give it some structure, a bit of cotton lining for comfort, and of course, thread that matched my denim.
Next, I searched online for a free baseball cap pattern. There are tons of them out there, some free, some you gotta pay for. I found one that looked relatively simple and straightforward, downloaded it, and printed it out. This pattern was a six-panel design, which seemed pretty standard.
Then came the cutting. I pinned the pattern pieces to my denim, interfacing, and lining, and carefully cut them out. It was a bit tedious, especially with all the curves, but I took my time to make sure everything was as accurate as possible. Accurate cutting is key!
After that, the sewing began! I started by fusing the interfacing to the denim pieces. This gave them a nice stiffness. Then, I sewed the six denim panels together to form the crown of the cap. This part was a little tricky because of the curves, so I used a lot of pins and went slowly, easing the fabric as I sewed. I basically stitched slowly and carefully.
Once the crown was assembled, I moved on to the brim. I cut two pieces of denim and one piece of stiff brim interfacing according to the pattern. I sewed the denim pieces together, right sides facing, leaving the straight edge open. Then I flipped it right side out, inserted the brim interfacing, and topstitched around the curved edge to give it a nice, clean finish.

Now, here’s where things got a little fiddly. I had to attach the brim to the crown. This involved a lot of pinning and easing, as the brim is curved and the crown is, well, kinda round. I stitched them together slowly and carefully, making sure to catch all the layers. This was probably the most challenging part of the whole project. I kept test fitting it too.
After attaching the brim, I sewed the lining together in the same way as the denim crown. I then attached the lining to the inside of the cap, sewing along the bottom edge. This gave the cap a nice, finished look and made it more comfortable to wear.
Finally, I added a sweatband to the inside of the cap. This is optional, but I think it makes a big difference in terms of comfort. I just used a strip of soft cotton fabric and sewed it around the inside of the cap, right above the brim.
And that was it! My trendy baseball cap was complete. It wasn’t perfect, but I was pretty happy with how it turned out. Plus, I learned a lot about hat construction in the process. It was a fun way to use up some fabric scraps and create something unique and stylish. I wore it the next day to the grocery store!
Some things I would do differently next time:

- Pay closer attention to the seam allowances when cutting.
- Use a slightly heavier interfacing for the brim for more stiffness.
- Try a different style of brim, maybe a flat brim.
Overall, it was a really enjoyable project, and I’d definitely recommend giving it a try if you’re looking for a fun and relatively easy sewing project. Grab some fabric and just get after it!