Embroider a Bucket Hat for a Fishing Fan

Looking for the perfect gift for the angler in your life—or want to make a fun, custom bucket hat for your next outdoor adventure? This quick project is perfect for any fishing fanatic and comes together easily with the right tools and tips. Learn how to embroider a bucket hat, whether it’s readymade or made fro a favorite pattern.

We’re spotlighting the “Bite Me Bass” embroidery design from Embroidery Library, stitched with Sulky 40 wt. Rayon Thread for eye-catching color and sheen, and stabilized with Sulky Stiffy to keep the design crisp. Let’s dive in!

EMBROIDER A BUCKET HAT – SUPPLIES

• Bucket Hat (cotton or cotton-blend preferred)
• “Bite Me Bass” design from Embroidery Library
• Sulky 40 wt. Rayon Thread in shades to match your design
• Sulky Stiffy™ Stabilizer (medium-weight tear-away)
• 60 wt. Bobbin Thread
• Size 90/14 Embroidery Needle
• KK 2000™ Temporary Spray Adhesive
• Removable chalk or fabric marker

BUCKET HAT PREP

• Choose Placement
  Bucket hats typically have panels and a brim. For this design, the top of the hat has the most surface area, so for larger designs choose this placement. The front crown (above the brim, between seams) is also a great choice, if the design is small enough to fit there without interfering with the seaming details. Use a removable fabric marker or chalk to mark the design center cross marks.

• Hooping
  Turn the hat inside out and flatten the embroidery area. Hoop a piece of Sulky Stiffy Stabilizer and place the hoop onto the machine. Direct the machine to run a baste-around-design perimeter basting function. Perform this step on the stabilizer only. Then, remove the hoop from the machine. Mark the design center cross marks onto the stabilizer for easier visibility. You can use a template to mark the cross marks or the inner hoop markings, if applicable.

• Hoopless Bucket Hat Embroidery
  Align the hat marked lines with the stabilizer markings, making sure the hat fabric is smooth and centered. Use KK2000 Temporary Spray Adhesive to secure the hat to the stabilizer, once satisfied with the placement.

EMBROIDER THE HAT

• Thread the machine with Sulky 40 wt. Rayon Thread and install a 90/14 embroidery needle. Rayon thread adds a beautiful shine and smooth finish, especially for designs with water or nature elements.

• Check the design orientation to match your chosen placement.

• Embroider the design, watching closely to guide any extra fabric out of the way. You’ll need to babysit the machine to keep the brim or other parts from bumping the needle arm during the stitchout. be ready to stop/start the machine as needed throughout the process.

HAT FINISHING

• Once the embroidery is complete, remove the hat from the hoop and carefully clip the jump threads on the right and wrong side.

• Then, tear away the Sulky Stiffy stabilizer from the bucket hat wrong side.

• If needed, use a small iron to press the area (from the inside) if needed, avoiding direct heat on the threads.

• Step back and admire your custom fishing hat—ready to turn heads at the lake, river, or wherever the fish are biting.

Why This Combo Works:

• Sulky Stiffy Stabilizer is ideal for firming up the hat’s structured fabric and provides excellent stitch stability for bold designs.

• Sulky 40 wt. Rayon Thread gives a vibrant, high-sheen look that holds up well and adds professional polish.

• A 90/14 embroidery needle is just the right size to handle the thickness of a bucket hat’s weave and stabilizer combo, without skipping or breaking.

Whether you’re stitching for Father’s Day, a fishing tournament, or just for fun, this project is a catch. Add a custom saying, initials, or keep it simple with the “Bite Me Bass” design—it’s sure to make a splash!

🎣 Tag @SulkyThreads with your finished hat! We’d love to see what you reel in.