Tutorial for creating a smaller sized Hoth hat.
Finished Hat (shown on the left is the "winter" version which is fully batted, on the right is the "con" version, created with batting only in the quilted neck piece.) :
If you would like the pattern for the smaller sized Hoth hat, contact me via email (it can be found in my profile under "Contact"). You will need 1 yard of off-white cotton material. I used a quilter's cotton from JoAnn's (be sure to pre-wash your fabric). You will also need ½ yard of fusible interfacing, some heavyweight stabilizer, a piece of plastic such as polystyrene, a package of double fold bias tape in "Oyster" and one in "Taupe", thin polyester batting, a scrap of tan fabric, and thread to match your fabrics.
"Con" version: Every piece except the lower front brim and neck piece get interfaced. The upper front brim will also need a piece of heavy weight stabilizer in addition to the interfacing. The lower front brim needs a piece of polystyrene (see the template that comes with the pattern for a guide). The neck piece needs batting.
"Winter" version: Every piece except the lower front brim and upper front brim need batting. The lower front brim needs a piece of polystyrene (see the template that comes with the pattern for a guide). The upper front brim will need a piece of heavy weight stabilizer and fusible interfacing.
The remainder of the tutorial shows the "con" version.
Lay out the quilting lines on one part of the neck piece using a dressmaker's pencil or tailor's chalk. After the quilting lines are marked, layer the two fabric neck pieces with the batting in the middle and zig zag or surge the edges to keep it from shifting.
Then, pin generously with quilter's pins and sew along the lines, removing pins as you sew. I like to sew all the lines in one direction first, starting in the center and moving out toward the edges. Then, I turn the piece and sew the lines in the opposite direction, again starting with the line in the center and moving toward the edges.
At this point, I hand wash the neck piece to remove the lines from the dressmaker's pencil. Hang to dry. When it is dry, lightly iron it.
Next, you will need to open up the Taupe bias tape and pin the shorter edge to the back brim. Sew. (*Note, be sure you pin and stitch the shorter edge of bias to all the pieces that will require bias tape in this way)
Pin a section of the Taupe bias tape (still folded) to the upper front brim, being sure there is enough of the brim below the tape for a seam allowance.
You need to top stitch only the top edge of this piece of bias tape, leaving the lower edge free. Then, unfold a new section of the Taupe bias tape and pin it to the curved edge of the upper front brim. Sew.
Unfold the Taupe bias tape and pin to ONLY ONE section of the lower front brim. Sew.
Next, you need to make sure both lower front brim pieces line up as you pin the other edge of the bias tape to the second piece of lower front brim. Sew.
Turn right side out and press, making sure that the seams on the inside are lying flat, facing forward toward the fold of the bias tape.
Insert the plastic lower front brim into the fabric lower front brim. Adjust the size of the plastic brim if needed.
Unfold the Oyster bias tape and pin to the neck piece. Sew. (*Note: be sure that the bias tape folds to the BACK of the neck piece.)
*The next few steps detail a sort of "stitch-in-the-ditch" type of stitching that the original Hoth hats utilized to sew the back side of the bias tape.*
After you have sewed one edge of the bias tape down, fold the rest of the bias tape over the raw edge toward the back.
Pin from the front, just along the edge of the bias tape, being sure the pin catches the bias tape in the back (see first picture). Sew on the top, along the edge of the bias tape, removing pins as you sew.
This is what the stitching will look like from the front.
This is what the stitching will look like from the back.
*All pieces that require bias tape will be sewn this way with the exception of the lower front brim.
Sew the sides of the hat together at center front and center back. Sew to top of hat. Be sure to zig zag or surge the edges to prevent fraying.
Top stitch around the rim of the hat about 1/8" away from the seam, making sure that the seam allowance is facing toward the rim of the hat and not the top.
There are 5 "tabs" for the goggle strap on the quilted neck piece. Two are larger and three are smaller. Create the tabs out of your scrap of tan fabric. The smaller tabs are 1" wide by 2½" long. The two larger tabs are 2½" wide by 3" long (be sure to allow extra for seam allowance).
Sew the small tabs like a tube, leaving both ends open. Turn & press. Zig zag or surge open ends. Sew the bottom and sides of the larger tabs, being sure to round the corners a bit. Turn & press. Zig zag or surge open tops.
Cut 1" white Velcro the width of each tab. Fold one zig zagged end of each tab under and sew the fuzzy portion of the Velcro over the folded edge.
Fold the neck piece in half to find the center back. Center one small tab over the center back and pin in place. Arrange the remaining tabs evenly on either side of the center tab, with the two larger tabs on each outer end.
Fold under the tops of the large tabs and place just a little below ½" under the top edge of the quilted neck piece. Pin in place. Fold under the tops of the remaining 3 smaller tabs and place them so that the bottom edge is in line with the bottom edge of the larger tabs. Pin in place.
Top stitch all tabs to the quilted neck piece, being sure to match your thread to the tabs.
Match the scratchy side of the Velcro to the fuzzy side of the Velcro. Pin the scratchy side to the quilted neck piece. Pin the tabs out of your way, and stitch the Velcro to the quilted neck piece. Remove pins, and close tabs.
Pin the back brim, upper front brim, and lower front brim to the hat. Sew.
Pin the neck piece to the hat. Sew.
For a more finished look, unfold the Oyster bias tape and sew to the raw seam, fold over and sew closed.
Sew a 1" tube of scrap off-white fabric. Sew a square of Velcro to the closed end of the tube. Sew the opposite end of the Velcro to the left side of the neck piece. Zig zag or surge the end of the fabric tube, fold to the back, and sew to the right side of the neck piece.
This is what the chin strap should look like when closed.
You will also want to hand stitch the bias tape where the upper and lower front brims meet.
There you have a smaller sized Hoth hat. To see my previous tutorial on the original sized Hoth hat, click HERE.