Mayer's New Hat

Since it's National Sewing Month, I am sharing some of my recent projects. This project severed two purposes: #1- Mayer has outgrown all of his bucket-style hats. I like them for the summer because they cover more than a baseball cap. #2- I was able to use scraps fabric I already had in my stash.

I used this pattern, but I didn't follow it exactly. Sewing with recycled materials, I am usually trying to save as much of the material as I can, so I only use 1/4" seam allowance. This pattern calls for 1/2" seam allowance and I kept forgetting. That would probably be why the hat fits Tate and me better than Mayer!
I also didn't have time to finish the brim seam like the pattern called for. I knew it would require measuring and ironing and I was in a time crunch to finish it before we went to the lake. I opted to use 2 different colors of thread, since the hat is reversible, and used an overcast stitch so it at least it wouldn't unravel too much when we wash it.
Another modification I made was using a t-shirt, instead of fusible interfacing, to give it stability. I was hoping by adding the t-shirt it would help absorb sweat better. I don't know if it works or not because he chose to wear a hat that was too small all weekend! :)