Our Blog TIPS AND TRICKS 8 Simple Ways to Make Hats Fit Smaller Heads

Jas Fashion > 13 June 2025

At Jas Fashion, we understand that while most adult head sizes fall within a narrow range—typically 55–57 cm (or 54–56 cm for women after hair loss)—there are still many beautiful individuals whose head sizes fall below this range. If your head is smaller than average, you're not alone—and you deserve hats that fit just right without compromising on comfort or style.
That’s why Jas Fashion offers complimentary hat modification on most styles. But we also know many of our customers enjoy trying simple DIY solutions at home. Here are a few tried-and-true techniques to help make your hat fit more snugly:

1. Layering Technique

This is one of the easiest and most effective ways to fill in space—especially useful when the weather is cool. Simply wear a head liner, cotton beanie, bamboo cap or a Jas Halo Hair Extension Band underneath your hat to gently increase your head’s volume.

Using Layering Tricks for Reducing Hat Circumference
This technique also works well for those with total hair loss. Please go to the following blog for the headwear suitable layer technique.

Finding the Perfect Fitting Headcovers

2. Add Darts

If the hat material is soft, adding darts is often the most popular and easiest DIY method to reduce hat size. A dart is a small tuck sewn into the fabric to create shape and take in excess material.
Darts can be a single large fold or multiple smaller ones spaced evenly around the crown.
You can sew darts by hand or with a sewing machine.
For a clean look, darts can be invisible (stitched inside the hat) or visible (stitched outside as a design detail).
Hand-sewn darts can be dressed up with a button, fabric flower, or brooch.
Some people even twist or fold the dart to create a ruched or gathered look.
This simple technique can make a big difference in both fit and appearance, especially for soft fabric hats.

Darts Styles for Reducing Hat Circumference

3. Sew an Elastic Band at the Back

Attaching a piece of narrow elastic at the back can pull in the hat for a snugger fit. This works particularly well with soft hats and turbans. For more advanced sewists, the elastic band can also be neatly concealed between layers.

Using Elastic Bands for Reducing Hat Circumference

4. Fold and Tuck the Cuff

For soft hats with a cuff or brim, try folding up a portion of the fabric to reduce the depth. You can stitch it in place for a permanent fix or simply tuck it in temporarily. This technique is quick, reversible, and helps reshape the crown without sewing.

Folding Up Cuffs to Reduce Headwear Circumference

5. Trim and Sew for a Permanent Fix

If you (or someone you know) can sew, you can trim away excess fabric and re-sew the back seam to adjust the hat’s size permanently. This is ideal for structured hats that are too large across the crown or base.

6. Add an Extra Sweatband, Headband, or Sizing Tape

Inserting an additional sweatband or soft headband inside the hat can reduce size and improve grip. This is especially helpful for sensitive scalps—use bamboo or cotton headbands for comfort.
Alternatively, use hat sizing tape or foam inserts (commonly used in sun hats and fedoras). These can be placed under the sweatband or lining.

Using Hat Sizer to Reduce Headwear Circumference

7. Insert a Drawstring

For lined hats or hats with a built-in sweatband, inserting a drawstring between the outer shell and lining/sweatband can be very effective. Simply thread a thin cord or ribbon around the inner crown area and anchor it at two or three points to keep it in place. Once tied, it helps shape the crown and make the fit more secure.
In the image below, the drawstrings or fabric straps are external and also serve as a decorative design element. While they’re visible and stylish, they still work well to reduce crown size.

Using drawstring to Reduce Headwear Circumference
For DIY purposes, we recommend using a thinner cord and placing it inside the hat, hidden between the lining and outer shell.
This technique works well with hats that have sweatbands or double layers.

8. Use a Sash or Headband to Adjust Fit

Sometimes, all it takes is a well-placed sash or fabric band to improve how a hat fits and looks—especially for soft hats and turbans.
In the images below:
Image 1: A wide sash is wrapped around the hat and styled into a decorative rosette at the side. This not only adds volume but can help subtly pull in the hat around the crown.
Image 2: A lightweight chiffon headscarf is tied at the back over the hat, creating a flattering shape while drawing in the fit at the nape of the neck.

Using Hat Sizer to Reduce Headwear Circumference
These techniques are:

Non-permanent and fully adjustable
Perfect for adding style and structure
Ideal for chemo headwear or sensitive scalps

You can use existing scarves or purchase styling bands separately. If you’re layering for warmth or volume, this is a simple yet beautiful trick to try.