Surgical Hats: Step-by-Step Sewing Instructions With

Photos for Sergers(Adaptable for Sewing

Machines)By Lancaster County 4-H volunteer Rhonda Griess

Cut out pattern pieces. You can fit two cap patterns on a 13” (3/8 yd) piece of fabric

Fold

Part 1: Hat Elastic

1. Serge finish the straight edgeof the hat top piece.

3. Straight stitch close to fold to create casing.

2. Fold 3/8” to inside and press.

Part 1: Hat Elastic 4. Cut a 3” piece of ¼” elastic. Attach a safety pin to one end.

5. Work elastic through casing. When it is flush with the end, stitch end into place.

6. Finish working elastic through casing, remove pin and sew elastic into place on that end, too.

Stitch Stitch

Part 2: Sewing Top to Side1. Line up the center of top to the center fold of the side piece, and pin in place.

2. Pin around top piece, matching elastic ends of the top to the marks of the side piece.

Part 2: Sewing Top to Side3.Using a serger, stitch all the way around the piece without stopping. Start on the short edge before the hat top. Remove pins as you sew.

Part 2: Sewing Top to Side - photosFinishing attaching top Serging final edge Done serging

Part 3: Finishing Hems

1. Fold over & press short ends at ¼”.2. Fold over and press inside edges that connect to hat top, at ¼”.

Fold & Press

Part 3: Finishing Hems

3. Fold long end to meet inside edge (1”) and press all the way around. A tailor’s ham works well for this step. Pin short ends in place.

Fold & Press

Fold & Press

Part 3: Finishing Hems4. Starting on the short edge, zig zag stitch bottom hem of long piece close to edge (1/4”). Sewing on the inside is helpful for this step.

Part 3: Finishing Hems

5. With the right side up, zig zag top stitch the bottom edge of hat, with the sergededge pressed toward the side of the hat. Start at the narrow tie end, as shown.

The completed hat!