Create a Pattern

• 1). Measure to determine the size of the old-fashioned bonnet. You can do this by either measuring the person's head or the inside of a hat worn by the person. Do not measure or use a baseball cap because they are too soft to allow an accurate measurement. To measure the person's head, wrap a measuring tape around the head starting at midway down the forehead and round the back of the head just above the ears. Write this measurement down.
  
  
• 2). Create a pattern for the old-fashioned bonnet. Cut open a paper bag to make a long piece of brown paper. If you need to, tape more than one bag together to make a larger piece of paper.
  
  
• 3). Divide the head measurement in half. For example, if your head is 22.5 inches, the measurement will be 11.25 inches.
  
  
• 4). Make half of an oval that matches the general shape of the head. Once you have established this half oval, draw another half oval beside it that is exactly 4 inches away. Connect the two ovals at the top and bottom so that the end result should look like one solid band.
  
  
• 5). Cut this band. Trace around it to create two more pattern pieces like it. Create a fourth pattern piece that looks like one solid half oval by laying an yardstick along the opening of the band and draw one solid line to connect them. Cut this pattern piece out as well.
  
  

Lay Out the Pattern

• 1). Buy the fabric needed for the old-fashioned bonnet. The fabric can be felt, corduroy, velvet, tapestry, burlap, suede, leather or anything else period appropriate. To determine the exact amount needed, measure the height of the half-oval and multiply the total by "4." Round up that number to the nearest half yard. You may find the total is close to 2 yards or more. Buy interfacing as well. You will need half as much interfacing as the fabric.
  
  
• 2). Lay the interfacing on the table and the fabric on top of it. Line up the fabric so that the left-hand edge of the fabric matches the left-hand edge of the interfacing, but the right-hand edge of the fabric extends beyond the interfacing's right-hand edge. The fabric should be right-side up.
  
  
• 3). Fold the fabric and interfacing on the left so that the left hand edge nearly lines up with the center of the fabric. Fold the right-hand edge of the fabric so that it nearly lines up with the center of the fabric. If you have done this correctly, you will have two folds forming the left- and right-hand edges of the fabric.
  
  
• 4). Lay two of the bands on the left side of the fabric so that the ends of the bands are against the folded outer edge. Pin them in place with straight pins. Pin the solid half oval and half oval band on the right hand side against the right-hand fold. Trace around the pattern pieces with tailor's chalk. The half oval bands will form the brim of the old-fashioned bonnet while the solid oval will form the crown.
  
  
• 5). Cut out the fabric pieces. Remove the paper pattern, but keep the fabric pieces pinned together. Create two seam allowances by drawing two lines along the inner and outer curve of the half ovals that is 1/2 inch from the inner and outer edges. Repeat this process with all the pattern pieces.
  
  

Assemble the Pieces

• 1). Unpin one of the brim pieces and open it. Lay it right side down on the table. Lay one of the pieces of interfacing on top of the fabric and pin them together. Sew along the seam allowance closest to the outer edge. You can do this either with a sewing machine or a needle and thread. Lay the fabric so that the right side faces up.
  
  
• 2). Lay another brim piece on top of the fabric so that the right sides are together. Secure them with straight pins. Sew the three pieces together by sewing along the outer seam allowance.
  
  
• 3). Cut triangular notches into the outer edges of the fabric, being careful not to cut the thread. Turn the fabric pieces inside out so that only the right sides of the fabric are revealed and the interfacing is tucked away, out of sight. Use a ruler to push the seams gently out so that the fabric is perfectly oval. Press the fabric flat.
  
  
• 4). Pin the inside of the brim and sew along the inner seam allowance. Lay the third brim piece on top of the other pieces so that the right sides are together. Pin it in place. Sew along the inner seam allowance with very loose stitches. Test fit the fabric to see how well the brim fits. Take note of any adjustments that need to be made. You can make these adjustments with ribbon later on in the process. Gently rip out the loose stitches with a seam ripper.
  
  
• 5). Open the crown piece and lay it right side up on the table. Lay the third brim piece on top so that the right sides are together. Pin the pieces together. Sew along the outer seam allowance. Turn the fabric so the right sides are facing out. Gently press the seams out; press them flat.
  
  

Sew the Old-Fashioned Bonnet Together

• 1). Lay the crown on the table, right side down. Lay the brim pieces on top. Sew along the inner seam allowance of all the brim pieces. This attaches all the pieces together. Do not sew through the crown. You can also do a zigzag stitch along the seam to reinforce the seam further.
  
  
• 2). Add a contracting ribbon to the outside of the bonnet. Put the old-fashioned bonnet on the wearer and tie the ribbon in place in the space between the edge of the crown and the beginning of the brim. If needed, tie the ribbon in such a manner so that it cinches the hat more tightly around the wearer's head.
  
  
• 3). Stick an ostrich feather into the ribbon for the crowning touch. If necessary, you can pin or sew this feather in place.