Cotton voile headband measuring 3.5" (89 mm) wide by 15.5" (39 cm) long with covered elastic measuring 0.5" (13 mm) wide by 4" (10 cm) long.
- Woven fabric, like lightweight cotton or silk
- 0.5" (13 mm) wide elastic--you'll need a length of about 4.5" (11 cm), but you can wait to cut it until the fitting stage
- Safety pin or loop turner
Measuring and Cutting
- Main Piece: Cut 1 rectangle from your fabric as shown in Diagram 1. The width range of 4.5" (11 cm) to 12.5" (32 cm) results in finished headband widths ranging from 2" (51 mm) to 6" (15 cm), respectively. Multiply your desired finished headband width by two and add 0.5" (13 mm) to determine the exact fabric width to cut.
- Connector Piece: Cut 1 rectangle from your fabric as shown in Diagram 1.
Note: Any grainline orientation should be fine, but laying the long sides of the rectangles crosswise (i.e., perpendicular to the selvage) will use the least fabric yardage.
- Fold the short sides of the main piece in half with right sides together and, using a 0.25" (6 mm) seam allowance, sew the long raw edges together to create a tube as shown in Diagram 2. Repeat with the connector piece.
- Turn the main piece right side out and press so that the seam is positioned at center back (CB). Repeat with the connector piece. Use a safety pin or loop turner to turn the pieces right side out if needed.
- Insert the elastic inside the connector piece using a safety pin or loop turner.
- Sew the elastic and connector piece together at one end with a 0.25" (6 mm) seam allowance as shown in Diagram 3. (On the other end, just leave the end of the elastic sticking out for now; you can pin the end of the connector piece to the elastic to keep it in place if needed).
- Mark the short ends of the main piece about 0.375" (10 mm) away from each long (folded) edge as shown in Diagram 4. In between the markings on each end, make pleats as needed so that the width in between the markings matches the width of the connector piece, which in this case is 0.625" (16 mm). If your main piece is on the narrow side, try one knife pleat in the center; if it's on the wide side, try multiple knife pleats. You can also try an inverted or box pleat as shown in Diagram 4. Pin or baste stitch the pleats to secure them.
- Lay the main piece down with the front side facing up (i.e., CB seam facing down). On top of the main piece, lay the connector piece down with the back side facing up (i.e., CB seam facing up), aligning the edge of the connector piece that is sewn to the elastic with one of the ends of the main piece. The connector piece should be laying on top of the pleated portion of the main piece and should fit just within the markings you made on the main piece. Fold the short sides of the main piece 0.375" over the connector piece (the folded sides will overlap), and sew all layers together with a 0.25" (6 mm) seam allowance as shown in Diagram 5.
- Turn the headband right side out and test the fit by trying on the headband while stretching the elastic to the unattached end of the main piece. Cut elastic to desired length.
- Repeat Step 4 with the other ends of the elastic and connector piece.
- Repeat Step 6 with the other ends of the connector piece and main piece.
- Turn the headband right side out.