How to sew a jester hat: sizes, steps and tips

To sew a jester hat, make six stuffed points, join them to a folded head band, close the top with a round crown piece and add a bell to each tip. The Sewzy Jester Hat takes about 90 minutes, is a beginner project and comes in four head sizes: Kid, Teen, Adult and Adult L.

TL;DR

• The Sewzy Jester Hat is a Premium beginner pattern in the app, about 90 minutes. It is not a free download.
• Sizes by head: Kid, Teen, Adult and Adult L.
• You need two or three colors, about ½ yard of each, and ¼ yard for the band and crown.
• Notions: 6 jingle bells (12 to 15 mm), polyester fiberfill and optional ¼ inch elastic.
• Seam allowance is ⅜ inch (1 cm), included in the pieces.

Is there a free jester hat sewing pattern?

This one is not free. The Jester Hat is a Premium pattern in the Sewzy app. Everything below explains how a jester hat goes together, so you can follow the method with any pattern, but the sizes, the point shape and the cutting guide come from the pattern itself.

What do I need to sew a jester hat?

• Fabric: wool or acrylic felt, quilting cotton, velvet, satin or crushed velour. Plan about ½ yard of each color, plus ¼ yard for the band and the crown.
• Interfacing: fusible interfacing on cotton points helps them hold their shape.
• Bells: 6 jingle bells, 12 to 15 mm.
• Stuffing: a handful of polyester fiberfill.
• Elastic (optional): ¼ inch elastic, cut to your head measurement minus 2 inches.
• Tools: a sewing machine, scissors, pins, a chopstick for turning and an iron.

What size jester hat do I need?

Choose your size by head. Measure around the head where a hat sits, and match it to the table. The pattern also lists a finished size for each, so check it before you cut.

The band strips are 5¼ inches tall and fold double into a 2¼ inch band. The hat sits on top of the head like a pillbox, with the points flopping outward. For a costume party, size up so the band slips on easily over hair.

How do I sew a jester hat, step by step?

These steps follow the six stages of the Sewzy pattern. Press as you go, because crisp points are what make the hat look neat.

1. Cut. Print your size and cut 12 point pieces as 6 mirrored pairs, with the fabric folded right sides together. Use 3 pairs in each of 2 colors, or 2 pairs in each of 3 colors. Cut the head band strip and the round crown top by the cover measurements, and add interfacing to the circle. Mark the circle edge and one long edge of the band into 6 equal parts.
2. Sew the points. Put each pair right sides together and stitch both curved edges from the tip to the base, leaving the base open. Trim the tip, notch the outer curve and turn the point right side out with a chopstick. Press. Stuff the top 3 inches lightly and hand-sew a bell to each tip.
3. Make the head band. Join the short ends of the band strip, right sides together, and press the seam open. Fold the loop in half lengthwise, wrong sides together, raw edges level, and press. For a snug fit, stitch a ½ inch channel along the fold, leave a 1 inch gap, thread in the elastic, join its ends and close the gap.
4. Add the points to the band. Pin the six points to the outside of the band, tips hanging down and bases level with the raw top edge, one at each marked sixth. Alternate the colors and let the bases meet edge to edge. Baste ¼ inch from the edge so the stuffed tips stay clear of the seam.
5. Attach the crown top. Place the crown circle right side down on the band, match its marks to the points and stitch all the way around through the circle, the points and both band layers. Finish the seam allowance with a zigzag or overlock stitch, unless you used felt. Press it toward the crown.
6. Finish. Flip the crown up and the band down. The band sits on the head, the crown closes the top and the six points flop outward with their bells. Topstitch the band ⅛ inch below the seam if you like.

Which fabric makes the best jester hat?

Felt is the easiest first choice. It does not fray, so the points need no turning: sew them wrong sides together ¼ inch from the edge for a raw-edge look. Quilting cotton gives bright prints but needs interfacing. Velvet and satin look rich and need gentle pressing from the wrong side.

A classic jester hat alternates two colors. Three colors give a carnival look. If you want bendy points instead of floppy ones, slide pipe cleaners inside rather than stuffing.

Common jester hat mistakes

• Over-stuffing the points. A light fill in the top 3 inches is enough. Heavy points drag the band down.
• Stitching the bells on too early. Sew them on after turning, so the thread does not catch in the seam.
• Wrong band size. Measure the head first. Choosing by age is less reliable than choosing by head.
• Skipping the marks. Six equal sixths on both the band and the crown keep the points evenly spaced.
• Washing felt. Spot clean felt hats. They do not like the washing machine.

More costume ideas

The jester hat pairs well with a cape or a fabric crown for a full dress-up set. Browse the costume sewing patterns, or read DIY Halloween costumes to sew for more ideas. If you are new to sewing, start with easy sewing projects for beginners. Download Sewzy on the App Store to get the Jester Hat pattern.