Turn a Shrunken Sweater Into a Retro Wool Beret

Nicole DIY, sustainable fashion, zero waste diy, handmade, hat, refashioning, sewing, vintage inspired, zero waste

While we’ve been pleasantly surprised with a very warm winter this year, the weather has turned cold lately, and it is definitely feeling like winter in Alberta again. Since it is only February (which means we’ve still got a ways to go before Spring) this is the perfect time to share one of my latest projects- a felted wool beret. Berets are not necessarily the warmest of headwear, but they do add a great vintage element to your winter ensemble, so I definitely consider them to be a fall and winter outfit staple.

While berets have risen in popularity the past few years, I have yet to come across one in brown. So, if you can’t find one at the store and you can’t knit or crochet one for yourself, what can you do? You can easily turn a shrunken sweater castoff into a felted beret!

I would not recommend that you take a perfectly good wool sweater and felt it, because wool sweaters can be expensive and it always seems like a waste to cut up something in good shape that someone could actually wear the way it is. However, there are so many wool sweaters in thrift shops that are no longer in good condition. Whether it’s due to the previous owner accidentally shrinking them, or that they are full of moth holes or runs, or even that they have stretched out of shape due to improper care, the thrift shops are full of them. This project is a perfect way to recycle and refashion those sweaters that are completely ruined and useless into something new!

I found this chocolate brown sweater years ago, but hadn’t yet figured out what to make. Since brown berets have proven difficult to find, I thought that this would be the perfect way to get the colour I wanted.

To Make Your Own, You Will Need:

• A 100% old wool sweater. Make sure it is real wool content, so it will felt for you. I know you can also use blends that have a high wool content, but I’ve never done that myself, so am not sure whether they felt differently or not.
• Needle & thread/ sewing machine
• Beret pattern- I used Tanith Rowan’s Grevillea Beret. (Tanith gifted me that pattern several years ago. You can see the first one I made here). Edited to add: Another free beret option is this style from Brittani of Untitled Thoughts. She has a free pattern download, as well a sewing tutorial. 
• Button to cover, or a decorative button of your choice 
• Elastic to make the hat fit tighter, optional

To Make the Hat:

My wool was already partially felted, so I cut the pieces out of the sweater and went from there, felting the final hat a little more at the end. After making this one, I was wondering whether you could also make it by cutting your pattern pieces out a bit larger and then felting the wool after you already have the hat sewn up. This might make the seam lines disappear a bit, and make the hat easier to form, but I haven’t tried it yet to know for sure.

But, in order to make the hat exactly as I have here, you are first going to need to felt your sweater, if it isn’t already shrunken. You can do this by putting the sweater into the washing machine with a little bit of laundry soap and washing it in hot water. It works better if you have a few sweaters in at the same time, so they can bump into each other and cause friction. You can also add a foam ball or flip-flop to help it felt even faster. Once you have washed your wool, take a look at it and see whether it has felted enough. If you want it to shrink a bit more, you can put it through the dryer, removing it before it is completely dry. Once the wool is good, let it dry.

Once your sweater is dry, it is time to figure out your pattern. There are several different ways to make a sewn beret; I chose to use Tanith Rowan’s Grevillea Beret, since I already had the pattern. This hat is made up of segments, giving it an octagonal shape. Her pattern has a more vertical shape to it and doesn’t lie flat, but since I wanted the hat to have a similar flat shape and fit to a traditional round wool beret, I made a couple of changes.

To adjust the pattern, I made a sharper angle on the bottom segments so they would be narrower at the bottom edge. This way the hat would lay flat back on itself.  I measured the inner circumference of a beret that I already had and made the opening of my pattern add up to 20″ circumference. I actually should have made the opening a little bit smaller, since the hat ended up stretching quite a bit, so I would recommend that you go at least an inch or two smaller than you want it to be, to account for stretch. The other change I made to the pattern was using a facing, rather than a hat band. (More on that in a minute)

Once you’ve chosen your pattern, it’s time to cut it out. Watch out for where the seams are in the sweater, you don’t want to accidentally cut across them, or you’ll end up with a bulky piece. Also, look for any areas that may have holes or other flaws, since they won’t have closed up during felting. I cut my pieces out of the sleeve and around the neckline to maximize the amount of fabric I would have left over to use for future projects. I also saved the bottom of the sleeve pieces including the cuffs, since I might make a pair of matching mittens in the future using this method here.

Once you’ve got your pieces cut out, it is time to sew them. Since the wool is felted, you won’t need to worry about it fraying, so you don’t need to finish the edges in any way. Sew together your pieces of the hat, excluding the hat band, following the instructions of your pattern.

Make sure to use a zig-zag rather than a straight stitch when sewing, since this is a stretch fabric.

Instead of making a flat hat band, I decided to made a round facing. The advantage of a facing, rather than a hat band is that it flips to the inside, so it is completely hidden. This is just a style preference, you could also use a flat hat band if you prefer. To make my facing, I measured the diameter across of the opening of my hat, then measured out 2″ and cut out the circle pattern piece. My sweater had a large enough section left to cut the facing in one piece, but you might need to cut it in 2 pieces and sew them together. If so, remember to leave seam allowances!

With right sides together, sew the facing to the hat.

Once you’ve got the hat sewn, it is time to form the shape of the hat. To make a form, cut a piece of cardboard into a circle the size you want your finished hat to be. I measured the beret I already had, to figure out what size I wanted. Since your hat will be wet, you need to waterproof the form, so place the cardboard piece inside a bag. I was originally going to use a dinner plate as a form (it was the exact size needed!) but then I wasn’t sure I would be able to get it out after the hat had dried without having to stretch the hat completely out of shape…or smash the plate! The cardboard turned out to be flexible enough to remove easily and it worked well.

Now, fill a basin or sink with hot water. Submerge the hat so it is completely wet, and then slightly agitate the wool. Once it is fully soaked, take the hat out and gently press the water out. Don’t wring it, or it will stretch too much- the wool will be quite floppy! Roll the wool in a towel to pull out most of the water.

Take your cardboard form and place it inside the hat. Smooth the seams flat and shape the hat around the form. The hat will shrink as it dries, so in order to keep the opening of the hat from pulling back too wide, sew a stitch around the inner edge and slightly gather it in. Once you’ve finished, it’s time to let it dry. I placed my hat directly onto my drying rack, which ended up leaving some marks from the rods on the wool that I had to steam out, so I would recommend either letting the hat dry on a fabric mesh sweater drying rack, or placing a towel across the bars of a drying rack for the beret to sit on top of.

Once the hat is dry, you can snip the gathering stitch from the edge and then take the hat off of the form!

Not all of my seams dried completely flat, so to help shape it a little bit more, I used a tailor’s ham (actually a towel wadded inside an old t-shirt) to steam press the hat into a smoother shape. Then I pressed it flat. Make sure to use a wet press cloth, dampen the wool and lightly go over with your iron while it’s on full steam, so you don’t scorch your wool and make it go shiny.

Once you’ve pressed the hat into shape, it is time to tack the facing edge down, sewing through the seams to hide the stitches. After I finished the hat and tried it on, I discovered that the wool was a lot stretchier than my other berets and was quite loose. One of my other berets has a soft elastic around the edge which works well to keep the hat in place, so I added a piece of elastic along the edge of this hat. Place the elastic between the facing and the top of the hat and stitch in place by tacking it through the seams in order to hide the stitches.

The final step is to add a button. You can either cover a button with wool, or use a decorative button. I wasn’t sure if I would be able to use a covered button because the wool was so stiff, but I actually managed to push the back/shank onto the button form. If your wool is too thick to use the shank to cover your button, you can cut a circle of felt, run a gathering stitch around the edge and gather it in around the button form. (Like making a fabric yo-yo) Since it’s not a functional button, it doesn’t need to have a shank on the back and you can just sew it on like that, with the raw edges hidden underneath.

Once the button is sewn on, your hat is done. There you have it- a vintage styled felted beret, without even having to know how to knit or crochet!

Have you ever made anything with felted wool before? It’s a lot of fun, since the wool is so easy to manipulate. We’ve got some more wool sweaters in our stash, and I am now wondering whether I should steal some of them to make some more hats….

Do you think you will try this and turn a shrunken sweater into something new?