How to Sew a Lined Reversible Winter Hat (Beginner-Friendly Tutorial)

Create Two Cozy Looks in One With This Simple Winter Hat Project

Why a Reversible Winter Hat?

A lined reversible fleece hat gives you two warm, stylish looks in a single project, and it is much more durable than a no-sew version. This hat is soft, cozy, washable, and surprisingly fast to sew — beginners love it, and experienced sewists enjoy customizing it with different fleece colors, prints, or seasonal themes.

A reversible hat is also a great scrap-buster project for leftover winter fabrics, making it perfect for handmade gifts or boutique stockings.

⭐ Materials You’ll Need

¼ yard anti-pill fleece

¼ yard fleece, jersey knit, or sherpa (lining)

Matching thread

Scissors or rotary cutter

Pins or clips

Sewing machine with a stretch stitch

✂️ Step-by-Step Instructions

Step 1: Measure the Head

Measure around the wearer’s forehead. Most adults measure 21–23 inches.

To ensure a snug fit, subtract 1 inch from the final width.

Step 2: Cut the Hat Pieces

Cut four pieces total:

2 pieces outer fabric

2 pieces lining fabric

Each piece should be:

Width: (head measurement – 1")

Height: 12 inches for a standard fit, 14–16 inches for a slouchy style.

Curve the top corners slightly to help the hat fit smoothly.

Step 3: Sew the Outer Hat

Place the two outer pieces right sides together.

Sew along the curved top and down one long side, leaving the bottom edge open.

Repeat the same for the lining pieces.

Step 4: Nest the Hats Together

Turn the outer hat right side out.

Leave the lining inside out.

Place the outer hat inside the lining so that the right sides of both fabrics face each other.

Clip or pin along the bottom edge.

Step 5: Sew the Bottom Edge

Sew all the way around the bottom edge, leaving a 3–4 inch opening for turning the hat right side out.

Step 6: Turn and Close

Pull the entire hat through the opening.

Push the lining inside the outer hat, smoothing the seam line with your fingers.

Close the opening with:

A tiny topstitch, or

A hand-stitched ladder stitch for an invisible closure.

Step 7: Topstitch (Optional)

Topstitching around the bottom edge:

Increases durability

Helps the hat keep its shape

Gives a professional finished look

Choose a longer stitch length for a clean topstitch on fleece.

🎨 Customization Ideas

Add a pom-pom between layers before sewing the bottom edge

Add ear flaps into the bottom seam for extra warmth

Use two fleece prints for maximum reversibility

Use Sherpa lining for ultra-warm winter wear

Add a small sewn-in label for boutique-style hats

💡 Sewing Tip

Use anti-pill fleece whenever possible — it lasts longer, washes better, and keeps its softness through winter wear. When sewing fleece, a slightly longer stitch (3.0–3.5) gives smoother seams.

🧵 Recommended Fabrics

Best Outer Fabrics:

Anti-pill fleece

Wool fleece

Sweater knit

Thermal knit

Best Lining Fabrics:

Fleece

Jersey knit

Sherpa

Soft stretch velour

🛍️ Want More Sewing Projects?

Visit The Needle Market for sewing patterns, winter sewing ideas, and handmade items: https://www.theneedlemarket.com

Explore more sewing patterns at my Payhip shop: https://theneedlemarket.shop

If you're looking for more DIY projects without a sewing pattern, visit my blog, thedesignersneedle.com