I love hats. I love sewing. But on the whole I don’t love sewn hats. The seams usually look out of place. But a cap like this is actually meant to be sewn and looks right that way.
I made this one for my dad, based on this tutorial. Rather than take apart an old hat, I carefully measured one, adding 5/8″ seam allowance along every edge. I used a milk bottle for the brim – it’s a bit stiffer than any of the cardboard I had in the house. If I made another one, I’d make the back of the hat a bit longer, but I’m pretty happy with the way this one turned out.