Sew a Child's Chef Hat: Easy Tutorial with McColl's M60 Pattern

Updated at: 20/03/2025

Let your little one unleash their inner chef with this adorable and easy-to-make child's chef hat! This tutorial uses the readily available and versatile McCall's M60 pattern, making the process surprisingly simple, even for beginner sewers. Forget expensive, store-bought options – you'll be amazed at how quickly and affordably you can create a personalized chef hat that will spark joy and culinary creativity in your child. Imagine the delight on their face as they proudly wear their handmade hat while helping in the kitchen or playing pretend.

This project is perfect for those wanting a fun and rewarding sewing experience without complex techniques. We'll walk you through each step, from preparing your fabric to adding the final touches, using the McCall's M60 pattern as our guide. Ready to get started? Let’s dive into the detailed, step-by-step instructions below.

Preparation and Safety Guidelines

Tools Needed

Fabric
Interfacing (fusible recommended)
Sewing Machine
Pins
Iron
Scissors

Safety Guidelines

Adult supervision is required at all times, especially when using sharp tools like scissors and needles.
Ensure all fabric edges are properly finished to prevent fraying and potential ingestion by young children. Use a zigzag stitch or serger.
Always check the finished hat for any loose threads or small parts that could pose a choking hazard before allowing a child to wear it.

Step-by-Step Instructions

Prepare the Brim
- Press interfacing to the brim piece (piece 21). Trim excess interfacing.
- With right sides together, stitch the ends of the brim piece together. Press the seam open.
- Fold down about ½ inch all around the bottom of the brim piece.
Prepare the Brim
Gather the Hat Top
- Gather the top part of the hat (piece 22) by stitching two lines of gathering stitches with long stitch length and loose tension (about 4).
Gather the Hat Top
Attach Brim to Hat Top
- Pin the gathered brim to the top of the hat at the back seam, pulling the gathering threads until it fits perfectly.
- Sew a tight stitch around the brim and top, catching everything. Remove gathering threads.
Attach Brim to Hat Top
Finish the Seam
- Fold the seam allowance under the brim and use a blind stitch or hem stitch to secure it to the inside of the hat.
Finish the Seam

Tips

Using fusible interfacing simplifies the process. While the pattern may suggest sew-in interfacing, fusible works just as well.
Gathering the top of the hat can take approximately 25-30 minutes.

Common Mistakes to Avoid

1. Incorrect Fabric Choice

Reason: Using a fabric that's too stiff or too flimsy can lead to a poorly shaped hat that doesn't drape well or hold its form.

Solution: Choose a medium-weight, stable fabric like cotton canvas or a lightweight linen for the best results.

2. Uneven Seam Allowance

Reason: Inconsistent seam allowances will result in a hat that is misshapen and doesn't fit properly.

Solution: Use a seam gauge to ensure consistent seam allowances throughout the construction process.

3. Improper Gathering of the Crown

Reason: Uneven or too tight gathering at the crown will create puckering and an unprofessional look.

Solution: Gently gather the fabric evenly and adjust the drawstring to create a smooth, even crown.

FAQs

What size range does the McCall's M60 pattern cover?

The McCall's M60 pattern typically includes a range of sizes for children, usually starting from toddler sizes and going up to larger children's sizes. Check the pattern envelope for the specific size range included in your version.

What type of fabric is best for making a child's chef hat?

Lightweight and easy-to-wash fabrics work best, such as cotton, linen, or even quilting cotton. Avoid anything too stiff or bulky as it will make the hat uncomfortable for the child to wear.