• Skip to primary navigation
  • Skip to main content
  • Skip to primary sidebar
  • Skip to footer

Pieced Brain

All about quilting, knitting, crochet, embroidery, free tutorials, quilting and crafting book reviews.

  • Start Here
  • Design a Quilt
  • Featured
  • Patterns
    • Patterns
    • Pattern Updates
    • Free Patterns
  • Tutorials
  • Programs & Workshops
  • Contact
  • Show Search
Hide Search

Sweats into Hat Tutorial

By Denise Russell

My husband’s old sweat pants had been neatly folded on my dresser for a week. Deformed after many washes to fit anyone, I wasn’t sure even the Thrift Store would take it.

Today, I looked at it with mischievous eyes… and took it to my quilt room. I searched for a piece of plain flannel, and the rest of history! I did record it, though, in case you have sweats which need to be put to good use!

Here is what you will need:

Old sweat pants
Flannel fat quarter (more if for bigger hat)
Hat, or template for hat
Thread, scissors, etc for sewing

Take a hat, or use template for correct hat size, place it over sweat pants (2 layers), trace and cut shape. Note: the combination knit + flannel will not stretch, so make sure you know the head size and add 1/4 inch seam allowance all around.

Place one piece of cut sweats onto folded flannel, using it as a template to cut the two pieces you will need.

With RST, sew one black (shell) to one burgundy (flannel lining) together on the straight edge. As you can see, I used the walking foot as I was anticipating bulky spots to sew over later. Do the same for the other black and burgundy pieces.

Press seams open, then matching colors pin and sew both parts of hat together (RST), all around, leaving about a three-inch opening on one of the curves. (I left it open on the black side by mistake, as it was going to be the shell… Next time, will make sure the opening is on the lining).

Pull hat inside out through the opening.
I used chopstick to smooth over the seams…

Turn in about 1/4″ on both sides of the opening, pin as you carefully follow the curved shape.

With matching thread, sew opening shut.
Press seams all around. Then, place lining inside shell.

Top stitch the straight edge, fold lining over shell, and you are done! I am going back to the quilt room to work with the remaining fabric. This was quick and fun!

Enjoy the Friday…

Share This:

Share
Pin
Post
Print

Filed Under: Tutorials, Uncategorized

Get free quilt patterns and tutorials, as well as blocks and quilts designed exclusively for subscribers.

Find out what is trending in the quilting world and learn new techniques to take your quilting to the next level!

Reader Interactions

Comments

  1. Marie Lismore says

    at

    Love the hat….great tutorial. Thanks for sharing. Marie ([email protected])

  2. Createology says

    at

    Very smart of you to put that sweats fabric to good use. Thank you for sharing your technique. Stitching Bliss…

  3. Sara says

    at

    Really great idea and awesome finish!!

  4. Friendship Crossing says

    at

    What a cute and crafty idea Denise, may have to borrow your idea sometime, so thanks for the fun tutorial!!

    Hugs,
    Tanya

Primary Sidebar

Denise Russell

Hello, I’m Denise and I love to design and make quilts. You can also find me knitting, crocheting, and making other crafts. Join me!
  • Bloglovin
  • Email
  • Facebook
  • Instagram
  • Pinterest
  • RSS

Get free quilt patterns and tutorials, as well as blocks and quilts designed exclusively for subscribers.

Find out what is trending in the quilting world and learn new techniques to take your quilting to the next level!

My Patterns On ETSY!

Fantastic Sales! Click to Save!

Fat Quarter Shop Quilting Fabrics and Supplies
Lowest prices on the best yarn - guaranteed at knitpicks.com
Various Logos for Indygo Junction
300 X 250 banner

QuilterBlogs

Footer

Disclosure of Material Connection:

The links above and some of the links in my posts are affiliate links: if you click on the link and decide to purchase something, I may receive a commission. I often receive books from publishers so I can review them on my blog and, at times, I may receive products to use and write about my experience with them. Read my privacy policy.

Recent Posts

  • Scrappy quilt with stars
  • Flannel quilt for beginners
  • Black and White modern quilt
  • Free star quilt pattern
  • Free pattern for a panel quilt
  • Scrappy Quilt with Liberty of London

Search

Archives

Categories

Copyright © 2025 Pieced Brain Quilt Designs LLC. All rights reserved. · Designed by Wacky Jacqui's Designs