Sunsational Sun Hat

Keep the sun out of your eyes with this gorgeous, spiral-textured sun hat that you can make for the whole family.

Have you ever spent a gorgeous summer afternoon squinting through the glare because you forgot a hat? I certainly have, and let me tell you, sunburned cheeks are not a good look on anyone.

Finding a store-bought sun hat that actually fits comfortably can feel like an impossible quest. They are either too tight, too floppy, or made of scratchy materials that make your head sweat.

That is why making your own is a total game-changer. You get to choose the exact yarn, control the fit, and create something beautiful that lasts for years.

For this project, I fell head over heels for Bernat Handicrafter Cotton Delux. Cotton can sometimes be tough on your hands, but this particular yarn is incredibly soft and glides right off the hook.

Today, we are diving into a gorgeous spiral design that flows beautifully from the crown all the way to the edge of the brim. It is a seamless, meditative project that you can easily finish in a single weekend.

Best of all, I have written this pattern in four different sizes. You can make matching hats for everyone from your little toddler to yourself!

Why You'll Love This Pattern

• Seamless Spiral Design: No ugly seam lines running down the back of your hat.
• Sturdy Brim: The clever stitch structure keeps the brim from flopping into your eyes.
• Family Friendly: With four sizes included, you can easily whip up matching sets for the kids.

Materials You'll Need

• Yarn: Bernat Handicrafter Cotton Delux (Worsted weight, Size 4 cotton). Olive and Seaspray make lovely options.
• Hook: Any crochet hook size needed to meet the gauge.
• Notions: 1.5 yards of 19-gauge millinery wire, a wire joiner, pliers (if using wire), and a yarn needle for weaving in ends.
• Yardage: 230 yards for Baby and Toddler sizes; 280 yards for Child and Adult sizes.

Gauge & Sizing

• Gauge: Your circle should measure exactly 5.5 inches in diameter after completing Round 9.
• Sizes included: Baby (6-12 Months), Toddler, Child, and Adult.
• Finished measurements:
  • Baby: 16.5-inch circumference, 6 inches tall
  • Toddler: 18-inch circumference, 6.5 inches tall
  • Child: 19.5-inch circumference, 7 inches tall
  • Adult: 21.5-inch circumference, 7.5 inches tall

Abbreviations & Stitch Instructions

• ch: Chain
• sc: Single crochet (If you need a refresher on basic stitches, check out our US to UK Crochet Chart).
• sl st: Slip stitch
• sk: Skip
• sc2tog: Single crochet two together (decrease)

Pattern Notes

• Skill Level: Easy to Intermediate.
• This pattern is written in US crochet terms.
• The item is worked in continuous rounds without turning.
• Tension Tip: Keep your stitches snug, especially on the brim, to help the hat hold its shape.
• Customization Tip: You can adjust the brim width to 3.5 inches or 4 inches depending on how much sun coverage you want.

Step-by-Step Instructions

The Crown (All Sizes)

Round 1: Begin by forming a magic ring. Chain 1, then place 7 single crochets inside the ring. Pull the starting tail firmly to close the center opening, and slip stitch into your very first single crochet to join. (7 sc)

Round 2: *(Chain 3, work 1 single crochet in the following stitch), repeat this sequence 7 times in total. Note that your final single crochet should land in the identical stitch as your starting chain-3. (7 loops)

Round 3: *(Work 1 single crochet inside the next chain loop, chain 3, work 1 single crochet in the next single crochet stitch), repeat this sequence 7 times. (7 loops)

Note: The stitch you skip in the subsequent rounds will be compressed and run continuously with the chain-3 that comes right before it.

Round 4: Work 1 single crochet in the next stitch, placing a stitch marker here to track the start of your round. *(Work 2 single crochets inside the next chain loop, chain 3, skip the next stitch, work 1 single crochet in the next stitch), repeat from * until you complete a single crochet in your marked stitch. Take out the marker. (3 single crochets in each solid section)

Round 5: Work 1 single crochet in the next stitch, marking this as your first stitch. Work 1 single crochet in the next stitch. *(Work 2 single crochets in the next chain loop, chain 3, skip the next stitch, work 1 single crochet in each of the next 2 stitches), repeat from * until only one chain loop remains. Work 2 single crochets in that final loop, chain 3, skip the next stitch, work 1 single crochet in your marked stitch, and remove the marker. (4 single crochets in each solid section)

Round 6: Work 1 single crochet in the next stitch, marking this first stitch. Work 1 single crochet in each of the next 2 stitches. *(Work 2 single crochets in the next chain loop, chain 3, skip the next stitch, work 1 single crochet in each of the next 3 stitches), repeat from * until only one chain loop remains. Work 2 single crochets in that final loop, chain 3, skip the next stitch, work 1 single crochet in your marked stitch, and remove the marker. (5 single crochets in each solid section)

Round 7: Work 1 single crochet in the next stitch, marking this first stitch. Work 1 single crochet in each of the next 3 stitches. *(Work 2 single crochets in the next chain loop, chain 3, skip the next stitch, work 1 single crochet in each of the next 4 stitches), repeat from * until only one chain loop remains. Work 2 single crochets in that final loop, chain 3, skip the next stitch, work 1 single crochet in your marked stitch, and remove the marker. (6 single crochets in each solid section)

Round 8: Work 1 single crochet in the next stitch, marking this first stitch. Work 1 single crochet in each of the next 4 stitches. *(Work 2 single crochets in the next chain loop, chain 3, skip the next stitch, work 1 single crochet in each of the next 5 stitches), repeat from * until only one chain loop remains. Work 2 single crochets in that final loop, chain 3, skip the next stitch, work 1 single crochet in your marked stitch, and remove the marker. (7 single crochets in each solid section)

Round 9: Work 1 single crochet in the next stitch, marking this first stitch. Work 1 single crochet in each of the next 5 stitches. *(Work 2 single crochets in the next chain loop, chain 3, skip the next stitch, work 1 single crochet in each of the next 6 stitches), repeat from * until only one chain loop remains. Work 2 single crochets in that final loop, chain 3, skip the next stitch, work 1 single crochet in your marked stitch, and remove the marker. (8 single crochets in each solid section)

Stop here for the Baby size. Your circle should measure 5.5 inches across. Proceed directly to the "Side of the Hat" instructions.

Round 10: Work 1 single crochet in the next stitch, marking this first stitch. Work 1 single crochet in each of the next 6 stitches. *(Work 2 single crochets in the next chain loop, chain 3, skip the next stitch, work 1 single crochet in each of the next 7 stitches), repeat from * until only one chain loop remains. Work 2 single crochets in that final loop, chain 3, skip the next stitch, work 1 single crochet in your marked stitch, and remove the marker. (9 single crochets in each solid section)

Stop here for the Toddler size. Your circle should measure 6 inches across. Proceed directly to the "Side of the Hat" instructions.

Round 11: Work 1 single crochet in the next stitch, marking this first stitch. Work 1 single crochet in each of the next 7 stitches. *(Work 2 single crochets in the next chain loop, chain 3, skip the next stitch, work 1 single crochet in each of the next 8 stitches), repeat from * until only one chain loop remains. Work 2 single crochets in that final loop, chain 3, skip the next stitch, work 1 single crochet in your marked stitch, and remove the marker. (10 single crochets in each solid section)

Stop here for the Child size. Your circle should measure 6.5 inches across. Proceed directly to the "Side of the Hat" instructions.

Round 12: Work 1 single crochet in the next stitch, marking this first stitch. Work 1 single crochet in each of the next 8 stitches. *(Work 2 single crochets in the next chain loop, chain 3, skip the next stitch, work 1 single crochet in each of the next 9 stitches), repeat from * until only one chain loop remains. Work 2 single crochets in that final loop, chain 3, skip the next stitch, work 1 single crochet in your marked stitch, and remove the marker. (11 single crochets in each solid section)

Your circle should measure 7 inches across. Proceed to the "Side of the Hat" instructions.

Side of the Hat (All Sizes)

To ensure a smooth, professional finish, the decreases in this section are intentionally staggered. The total stitch counts at the end of these rounds will remain consistent until you begin the brim. These decreases simply balance out the natural increases created by the spiral pattern. Stitch counts for larger sizes are listed in parentheses: Baby (Toddler, Child, Adult).

Round 1: Work 1 single crochet in the next stitch, place your marker here. Work 1 single crochet in each of the next 3 (1, 4, 4) stitches, work a single crochet decrease (sc2tog), then work 1 single crochet in each of the next 1 (4, 2, 3) stitches. *[Work 2 single crochets in the next loop, chain 3, skip the next stitch, work 1 single crochet in each of the next 4 (2, 5, 5) stitches, work a sc2tog decrease, then work 1 single crochet in each of the next 1 (4, 2, 3) stitches], repeat from * until only one chain loop remains. Work 2 single crochets in that final loop, chain 3, skip the next stitch, work 1 single crochet in your marked stitch, and remove the marker. (8 (9, 10, 11) single crochets in each solid section)

Note for Baby size: When the pattern indicates "1 single crochet in the next 0 stitches," simply skip that step entirely and proceed directly to the sc2tog decrease.

Round 2: Work 1 single crochet in the next stitch, place your marker here. Work 1 single crochet in each of the next 0 (4, 1, 1) stitches, work a sc2tog decrease, then work 1 single crochet in each of the next 4 (1, 5, 6) stitches. *[Work 2 single crochets in the next loop, chain 3, skip the next stitch, work 1 single crochet in each of the next 1 (5, 2, 2) stitches, work a sc2tog decrease, then work 1 single crochet in each of the next 4 (1, 5, 6) stitches], repeat from * until only one chain loop remains. Work 2 single crochets in that final loop, chain 3, skip the next stitch, work 1 single crochet in your marked stitch, and remove the marker. (8 (9, 10, 11) single crochets in each solid section)

Repeat these two rounds continuously until your hat measures 6 (6.5, 7, 7.5) inches from the top of the crown to the bottom edge. Once you reach this height, you are ready to begin the brim.

The Brim

For the best results, work this section with a slightly tighter tension to give the brim extra structure.

Round 1: Work 1 single crochet in the next stitch, place your marker here. Work 1 single crochet in each of the next 2 (3, 3, 4) stitches, work 2 single crochets in the next stitch, then work 1 single crochet in each of the next 3 (3, 4, 4) stitches. *[Work 2 single crochets in the next loop, chain 3, skip the next stitch, work 1 single crochet in each of the next 3 (4, 4, 5) stitches, work 2 single crochets in the next stitch, then work 1 single crochet in each of the next 3 (3, 4, 4) stitches], repeat from * until only one chain loop remains. Work 2 single crochets in that final loop, chain 3, skip the next stitch, work 1 single crochet in your marked stitch, and remove the marker. (10 (11, 12, 13) single crochets in each solid section)

Round 2: Work 1 single crochet in the next stitch, place your marker here. Work 1 single crochet in each stitch until you reach the next chain loop. *(Work 2 single crochets inside the loop, chain 3, skip the next stitch, work 1 single crochet in each stitch across to the next loop), repeat from * until only one chain loop remains. Work 2 single crochets in that final loop, chain 3, skip the next stitch, work 1 single crochet in your marked stitch, and remove the marker. (11 (12, 13, 14) single crochets in each solid section)

For a 3.5-inch Brim: Repeat Round 2 nine more times. Slip stitch into the next stitch to finish. The stitch count in each solid section will increase by 1 stitch every round, ending with 20 (21, 22, 23) single crochets per section.

For a 4-inch Brim: Repeat Round 2 eleven more times. Slip stitch into the next stitch to finish. The stitch count in each solid section will increase by 1 stitch every round, ending with 22 (23, 24, 25) single crochets per section.

Adding Wire to the Brim

Before adding your wire, I highly recommend steam ironing the crown of your hat. Work gently from the top down along the direction of the spiral. This helps even out your stitches. Keep the lace holes open while ironing, and avoid ironing the brim itself. Only use steam if your yarn is 100% cotton.

If you prefer not to use wire, you can simply work the final round following the same pattern without it. Otherwise, follow these steps to secure your wire:

Step 1: Slip stitch your yarn to the left side of any single crochet section. Position your millinery wire close to this slip stitch, leaving about 2.5 to 3 inches of wire free. It should extend past the middle of the solid section.

Step 2: Work single crochet stitches directly over the wire to encase it, continuing until you reach the next chain loop. *(Work 2 single crochets into the chain loop, skip the next stitch, work 1 single crochet in each stitch across to the next loop), repeat from * until you have about 2 inches of the brim left to crochet.

Step 3: Smooth out the stitches along the wire brim with your hands to ensure even tension. Using your pliers, cut the wire on the right side so it meets the middle of the single crochet section. Peel back a bit of the rayon covering and slide the wire end into your joiner.

Step 4: Trim the wire on the left side, leaving just enough (slightly over half an inch) to insert into the opposite side of the joiner. Slide it in, then use your pliers to crimp both sides of the joiner firmly so the wire cannot slip out. Crochet over the joined section to the first stitch, and slip stitch to finish.

Weave in any remaining yarn tails, and your beautiful sun hat is ready to wear!

Easy Variations & Custom Ideas

• Striped Spiral: Alternate colors every few rounds to create a striking candy-cane spiral effect. Learn how to transition colors cleanly with our Seamless Color Change Technique.
• Floppy Brim: Skip the millinery wire entirely if you prefer a relaxed, bohemian look that packs easily into a beach bag.
• Matching Accessories: Pair this sun hat with a lightweight summer bag like our One Skein Boho Bag for the ultimate beach-ready ensemble.
• Contrast Border: Work the final round of single crochets over the wire in a contrasting bright color to make the brim pop.
• Flower Appliqué: Stitch a beautiful crochet blossom onto the side of the hat band for a vintage, feminine touch.
• Colour ideas: Soft pastels like mint and lavender look lovely for kids, while neutral tones like cream, tan, and olive work beautifully for adults.
• Yarn substitutions: If you cannot find Bernat Handicrafter, Sable Sugar 'n Cream is a classic alternative, though it may feel slightly thicker.

Common Troubleshooting & Fixes

• Problem: The crown is bulging or forming a cone shape instead of laying flat.
  Fix: Your tension might be too tight. Try switching to a larger hook size for the crown rounds to allow the stitches to spread naturally.
• Problem: The brim is ruffling like a head of lettuce.
  Fix: You may have accidentally added extra stitches. Make sure you are skipping the correct stitch after each chain-3 loop as specified in the pattern.
• Problem: The hat is too small for my head.
  Fix: Check your gauge after Round 9. If it is smaller than 5.5 inches, you need to use a larger hook.
• Problem: The millinery wire is poking through the stitches.
  Fix: Ensure you are working your single crochets tightly over the wire, and make sure the joiner is crimped securely so the ends cannot slide out.

Care Instructions

Hand wash your sun hat in cool water with a mild detergent. Gently reshape the crown and brim while damp, and lay it flat on a towel to dry. Avoid machine washing or tumble drying, as this can distort the wire and shrink the cotton fibers.

Final Thoughts

There is nothing quite like the satisfaction of wearing a beautiful, handmade hat that you crafted with your own two hands. I hope you enjoy watching this lovely spiral design come to life on your hook this season!