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L&P 1008: Classic Ball Cap and Big Fat Trucker Hat Sewing Pattern for 18 inch dolls such as American Girl — unisex boy doll sports hat visor



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  • Digital file type(s): 1 PDF

Our CLASSIC BALL CAP replicates the full-size original, a staple of sports and casual wear since the 19th century, with six panels for a molded fit, ventilating eyelets on each panel, a "squatchee" (matching fabric-covered button) at the top, and an optional vent at the back for the look of an adjustable cap (and also, a useful place to put a ponytail!)

Our BIG FAT TRUCKER HAT is a trendy tweak on the classic silhouette, standing ever-so-slightly taller and wider, with a stiffly-interfaced double panel in front begging to be decorated in any way you choose, and mesh panels along the sides and back.

The Classic Ball Cap is rated EASY as the curved sections fit together in a series of straight seams. For an even simpler version, the eyelets and back vent can be omitted and a purchased shank button can be used instead of a self-fabric covered button. This is an ideal pattern for a beginner looking to start making doll hats.

The Big Fat Trucker Hat is rated EASY/INTERMEDIATE. Though the construction steps are similar to the Classic Ball Cap, mesh material can be trickier to work with than standard woven fabric. If you use nylon net or mesh, we highly recommend finishing the prickly edges with a serger so they don't catch in your doll's hair.

With both styles, Lee & Pearl's photo-illustrated directions and computer-drafted, guaranteed to- fit-together pattern pieces make construction as easy as possible.



1/8 yard light or medium weight woven fabric: cottons or wools – calico, twill, denim, chambray, flannel, tweed, etc. This pattern works best with fabrics that simulate the drape of a medium weight twill or denim – like a well broken-in pair of pants. If using a lightweight fabric like quilting cotton, fuse lightweight interfacing to each piece before sewing.

Lightweight fusible interfacing for the brim

1/2 yard single fold bias tape

1 – 3/8" to 1/2" self-fabric covered button (kits can be found with notions in fabric stores) or a small, domed shank button of your choice

6 – 1/8" eyelets or grommets and eyelet/grommet setting tool (these can be found with scrapbooking supplies in craft stores)

3" of 1/4" to 3/8" twill tape, grosgrain ribbon or elastic for optional back vent

Matching thread



Scraps of light or medium weight woven fabric for the front panel and brim

Fusible fleece interfacing for the front panel and brim (we used Pellon 987F)

1/8 yard mesh for the sides and back
We have tried a wide variety of mesh options and found that stiff nylon net (also called "specialty mesh") works well, as long as you double it. If you're feeling adventurous, there are mesh options everywhere: beach bags, recyclable grocery bags, even dollar store laundry bags. One option that worked very well was the mesh from an up-cycled full-size trucker hat. This material sews easily, molds nicely and doesn't need to be doubled.

1/2 yard single fold bias tape

1 – 3/8" to 1/2" self-fabric covered button

3" of 1/4" to 3/8" twill tape, grosgrain ribbon or elastic

Matching thread, including serger thread


Trim your hats with appliques, purchased or self-printed heat transfer designs, glue-on or hot-fix crystals, fabric glitter, fabric paint, embroidery, or anything else you might see on a full-size ball cap or trucker hat.


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We made the T-SHIRTS and TOPS shown in our photos using Lee & Pearl Pattern #1001: Unisex T-Shirts for 18" Dolls – https://www.etsy.com/listing/156525451/lp-pattern-1001-unisex-t-shirts-for-18?ref=shop_home_active_8 — AND Lee & Pearl Pattern #1031: Classic Wrap Dress and Peplum Top for 18" Dolls — https://www.etsy.com/listing/188684456/lp-pattern-1031-classic-wrap-dress-and?ref=listing-shop-header-2

We made the red nylon WINDBREAKER JACKET using Lee & Pearl Pattern #1010: Army Combat Uniform Bundle for 18" Dolls — https://www.etsy.com/listing/172330824/lp-pattern-1010-army-combat-uniform

To see our other patterns, visit the PATTERNS section of our Etsy store at https://www.etsy.com/shop/leeandpearl?section_id=15862176&ref=shopsection_leftnav_1

To see our selection of Fabric & Trim Kits, visit the FABRIC & TRIM KITS section of our Etsy store at https://www.etsy.com/shop/leeandpearl?section_id=15860795&ref=shopsection_leftnav_2


This pattern will be delivered as an instant download. After purchasing, you will receive a link to a PDF copy of the file. No paper copy will be mailed.

This pattern may be printed solely by the original purchaser. It may not be duplicated, redistributed, posted or resold without prior authorization from Lee & Pearl™. If you use this pattern to make items to sell yourself, we ask that you give Lee & Pearl™ design credit in the description of those items. Thank you!

Lee & Pearl™ is not affiliated with Mattel, American Girl® or any other company or organization.

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2,955 reviews

5 out of 5 stars
5 out of 5 stars

Loved this pattern! Easy to follow, makes up quickly. I jumped right in and made my first cap in leather, and it's just adorable. I highly recommend Lee and Pearl patterns.

bossross17 Jul 27, 2018

5 out of 5 stars

I made the ball cap and it is really, really, cute! Another perfect pattern from Lee & Pearl! I have always been amazed at how their patterns can take your sewing from good to looking great! Thanks again and please make many, many more patterns!!

Dawna Jun 9, 2015

5 out of 5 stars

I made the classic ball cap last night and it turned our very cute. The instructions were well written and easy to follow. Thanks!

Patti Milligan Jul 7, 2015

5 out of 5 stars

Pattern is rated Easy, and it truly is. The baseball cap goes together fast and looks adorable on an 18 inch doll. Can't wait to make more!

Lee Beasley Apr 8, 2014

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