DIY Hat Refashion: Adding Fabric Lining for a Professional Finish

Updated at: 13/05/2025

Have you ever loved a hat but felt its unfinished interior detracted from its overall appeal? A flimsy, scratchy lining can instantly cheapen even the most stylish headwear. This is where the magic of DIY hat refashioning comes in! Adding a fabric lining is a surprisingly simple yet incredibly effective way to elevate your favorite hat, transforming it from a well-worn accessory to a polished, professional piece. This simple upgrade not only enhances the hat's comfort but also significantly improves its durability and longevity, protecting the outer fabric from wear and tear. It's a perfect project for both beginners and experienced sewists, requiring only basic sewing skills and readily available materials.

This guide will walk you through a step-by-step process of lining your hat, resulting in a beautifully finished headpiece you’ll be proud to wear. From choosing the right fabric to carefully attaching the lining, we’ll cover everything you need to know to achieve a truly professional look. Ready to transform your hat? Let’s get started!

Preparation and Safety Guidelines

Tools Needed
  • Fabric adhesive (spray)
  • Masking tape
  • Lint roller
  • Scissors
  • Fabric
  • Hat
  • Fabric pencil
  • Iron (optional)
  • Upholstery needle (optional)
  • Sewing machine (optional)
Safety Guidelines
  • Always use sharp, well-maintained sewing shears or a rotary cutter for clean cuts to prevent injury and ensure accurate fabric placement.
  • Pre-wash all fabrics before starting the project to avoid shrinkage after the lining is sewn in. This will ensure a perfect fit and prevent unwanted puckering.
  • If using pins, handle them carefully to avoid accidental pricks. Consider using clips as a safer alternative, especially when working with delicate fabrics.

Step-by-Step Instructions

  1. Prepare the Hat

    • Remove the hatband from the inside of the hat.
    • Apply masking tape to the inside crown of the hat, leaving about 1cm from the edge.
    • Apply masking tape to the edge of the brim to protect it from glue.
    Apply masking tape to the edge of the brim to protect it from glue.Apply masking tape to the edge of the brim to protect it from glue.Apply masking tape to the edge of the brim to protect it from glue.
    Prepare the Hat

  2. Prepare the Lining Fabric

    • Iron it for a flat surface (optional), place the hat on the fabric, trace around it, cut the fabric, and cut notches around the edges for easier curving.
    Prepare the fabric: Iron it for a flat surface (optional), place the hat on the fabric, trace around it, cut the fabric, and cut notches around the edges for easier curving.
    Prepare the Lining Fabric

  3. Apply the Lining to the Brim

    • Apply fabric adhesive to the underside of the brim and the back of the fabric. Stick the two together, smoothing out any wrinkles.
    Apply fabric adhesive to the underside of the brim and the back of the fabric. Stick the two together, smoothing out any wrinkles.
    Apply the Lining to the Brim

  4. Finish the Brim Lining

    • Trim the excess fabric, being careful not to cut into the stitching. Tuck the remaining fabric under the stitching.
    Trim the excess fabric, being careful not to cut into the stitching. Tuck the remaining fabric under the stitching.
    Finish the Brim Lining

  5. Reattach the Hatband

    • Reattach the hatband using a sewing machine or by hand.
    Reattach the hatband using a sewing machine or by hand.
    Reattach the Hatband

Read more: DIY Stretchy Fingerless Gloves: Easy Sewing Tutorial

Tips

  • Use a lint roller to clean the hat before applying fabric.
  • Work quickly but carefully when applying the adhesive to avoid moving the fabric too much.
  • Trim the fabric in small increments to avoid cutting gaps.
  • Tucking the fabric under the stitching creates a professional finish.

Common Mistakes to Avoid

1. Incorrect Lining Size

Reason: Cutting the lining too small or too large will result in a poorly fitting or bulky hat.
Solution: Accurately measure the hat's inner dimensions and add seam allowances before cutting the lining fabric.

2. Uneven Seams or Puckering

Reason: Inconsistent stitching tension or improper handling of fabric during sewing can lead to uneven seams and puckering in the lining.
Solution: Use a walking foot or careful hand-sewing techniques, maintaining consistent tension and gently easing fabric as you sew.

3. Ignoring the Hat's Structure

Reason: Not accounting for existing seams, stiffening, or structure within the hat can lead to a lining that doesn't fit properly or sits awkwardly.
Solution: Carefully consider the hat's existing form and adjust the lining's construction to accommodate these features.

FAQs

What type of fabric is best for lining a hat?
Lightweight fabrics like cotton, silk, or lining fabrics specifically designed for hats work best. Avoid anything too heavy or stiff, as this can make the hat uncomfortable to wear.
How do I ensure the lining fits the hat perfectly?
Before sewing, carefully baste the lining fabric to the hat’s interior. This allows you to make any necessary adjustments to ensure a snug and even fit before permanently attaching it. Take your time with this step for the best results.