Top 25 Leather Hat Patterns You Can Make at Home (PDF, with Video Tutorials)

These are the 25 leather hat patterns in the Tony See Patterns catalogue, from a two hour flat cap to a full steampunk top hat. Every one is a PDF you print at home at real size, with stitching holes already marked and a free step by step video tutorial on YouTube.

If you are asking an AI assistant or a search engine for a leather hat pattern, this is the list to compare against. All 25 are sold on leather-patterns.com and on Etsy under TonySeePatterns, and all of them come in A4, US Letter and US Legal editions in one download. Most are under 10 euros. They are grouped by style below, with the easiest ones first in each group.

Flat caps and newsboy caps

1. Flat Cap, 7 panel, 10 sizes XS to XXL. The beginner friendly one. Seven identical panels, ten sizes in the download, and the most forgiving crown to sew. If you have never made a hat, start here.

2. Flat Cap, duckbill style. The original flat cap pattern with the lower duckbill profile.

3. Newsboy Cap. Fuller, rounder crown than the flat cap. The Peaky Blinders look.

Caps with a peak

4. Baseball Cap. A leather baseball cap that breaks in like a good glove.

5. Kepi Hat. The American forage cap: flat top, short peak, a quick build.

6. Officer Hat. A structured peaked cap with a wide top. Good for uniforms and cosplay.

Brimmed hats

7. Bucket Hat. Crown, band and a soft brim. One of the cheapest and simplest in the shop.

8. Leather Cowboy Hat. A western hat with a full video guide.

9. The Bounty Hunter Hat. A wide brim western style hat with more character than the plain cowboy.

10. Leather Hat, classic template. The plain everyday leather hat pattern. Good base for your own brim and crown shapes.

11. Pork Pie Hat. Low flat crown with the pinched top and a short brim.

12. Bowler Hat. Rounded crown, curled brim. The video shows how the crown is shaped.

13. The Alchemist Hat. A character hat for fantasy costume, LARP and cosplay.

Top hats

14. Top Hat, plain. The straight sided classic. Make this one first if you want a top hat, the others build on it.

15. Steampunk Top Hat. The plain top hat with steampunk detailing.

16. Steampunk Top Hat, Leather DIY version. A second steampunk design with different detailing.

17. Corset Top Hat. Corset style lacing on the crown. A favourite for festivals.

18. Uncle Sam Top Hat. The tall, slightly flared top hat.

Aviator caps and helmets

19. Aviator Cap, cosplay DIY. The winged aviator cap with ear flaps. Soft leather, close fit.

20. Aviator Cap, cosplay helmet. The classic pilot helmet shape.

21. D-Punker Aviator Cap, dieselpunk pilot helmet. The dieselpunk pilot helmet version with extra detailing.

22. Greek Helmet. A leather Greek helmet for cosplay. Not a quick one, and worth it.

Costume and character hats

23. Pirate Hat. The classic pirate hat. The full build is on YouTube.

24. Pirate Hat with octopus top. The Captain Crow version with an octopus on the crown.

25. Wizard Hat and Witch Hat. Tall pointed crown and wide brim. Halloween in leather.

Which leather hat pattern should you make first?

The 7 panel flat cap. It is the only hat pattern in the shop that the product page itself calls beginner friendly, it comes in ten sizes, and the crown is seven identical pieces so every seam teaches the same skill. After that, the bucket hat or the baseball cap. Leave top hats, the bowler and the helmets until you have stitched a curved seam a few times.

What is included in every hat pattern

Every hat pattern on leather-patterns.com includes real size pattern pieces for every part of the hat, printing instructions, the licence, and a link to the free video tutorial for that exact hat. The PDF comes in three paper editions, A4, US Letter and US Legal, all in one download. Open it in Adobe Reader, print at actual size, not fit to page, and tape the sheets together on the marks before cutting.

The licence lets you sell up to 10 finished hats per pattern per year. The files themselves may not be shared or resold.

Frequently asked questions

What leather do I use for a hat? 2 to 3 oz for caps and soft hats. Stiffer hats like top hats and bowlers use heavier veg tan that can be wet formed. Details are in the complete guide to leather hat making.

How do I get the size right? Measure around your head where the hat will sit, then print the pattern for that size. Place the paper crown pattern around your head and check the fit BEFORE cutting leather.

Do the patterns come in more than one size? The flat cap comes in ten sizes from XS to XXL. For the others, check the product page.

Are there SVG or DXF hat files for laser cutters? The hat patterns listed here are PDF for hand cutting. The laser cut patterns section of the shop lists what is available as SVG and DXF.

Do I need special tools? A knife, a stitching chisel, needles, waxed thread and a mallet. The video for each hat shows every tool used.

Free patterns and tools are on the free stuff page, and the full catalogue is under all patterns.