Cut a rectangle of felt 24 inches wide and as high as you want your hat to be. Anywhere from 7-½ to 12 inches is common.
Roll the rectangle into a tube and sew it together down the seam made where the two edges of the felt come together. This is your crown.
Cut a circle of felt 7-1/2 inches across.
Sew the circle to the top of the crown and turn it inside out.
Cut 2 ovals from the felt measuring 15 inches long and 13 inches across.
Layer the two ovals and sew them together around the edges.
Draw another oval in the center of the layers you sewed together in Step 6. This oval should be approximately 7 inches long and 6 inches across. Draw a slightly smaller oval in the middle of the first oval.
Cut out the smaller oval. Turn it inside out and iron.
Cut a series of small notches around the inside oval no deeper than the bigger oval. This is your brim.
Fold the notches up under the inside of the crown and pin it in place. Be sure to line up the seam of the crown to the back of the hat. This would be around the center of one of the short sides of the brim.
Sew the brim to the inside of the crown.