Want a digital copy of the pattern to scale so you can print it and cut out? Send me an email - larissa.fontenot@gmail.com or get it here: https://etsy.me/2UJQrHR Watch me make this scrub cap from start to finish! https://youtu.be/gc2cxrAx1mA Scrub caps if they are custom made are a huge deal for surgeons. So as my daughter was about to start general surgery residency, she asked me if I could make a custom scrub cap for her - I used to sew for people for 20 years back in Russia. I still love to sew, I am creative like that. So I went searching on the internet to find a pattern to make a scrub cap she wanted: really tight fit, with elastic band in the back and, of course, I know she is going to pull on those ties, so seams might break. That's where zigzag stitch comes in handy. I found bits and pieces online, and made up my own pattern. Decided to create a video tutorial too. Enjoy making scrub caps for your surgeon!

1. Surgeon’s Scrub Cap – DIY Step By Step Tutorial
(Want a digital copy of a pattern to scale so you can print it & cut out? Send me an
email larissa.fontenot@gmail.com)

2. You will need:
Paper to make the pattern – all measurements are in inches
9 inches of cotton fabric – standard 44 inch width
3 inches of elastic band
Black and red thread
Please wash, dry and iron fabric before you start cutting – it will shrink

3. Place side of the cap pattern on folded fabric
Second layer of fabric is below
Fold fabric along this edge
2 layers of fabric
1 layer of fabric

4. Once you cut your fabric, make sure to mark where you will
connect top part of cap to side part of your cap in the back

5. I used pins to mark where I will connect the top part of my
cap to the side part of my cap in the back on both ends of the
side part of my cap

6. Use hot iron to fold the curved edge of the side part one
time, beginning at your pins and to the ends of side of cap
part of your cap

7. Use hot iron to fold the curved edge the second time,
beginning at pins in wider part and ending at beginning of
straight end on both sides of side of cap part

8. Use hot iron to fold
the edge at both
short sides of straight
ends and bottom of
side part of your cap

9. Use zigzag stitch to secure curvy parts of your side piece
between the pins

10. Use hot iron to fold
bottom of side part of
your cap toward wrong
side of fabric making sure
your ends are folded in
two and edges are
aligned

11. Use zigzag stitch to sew edges of ties
of your cap together and bottom fold
of your cap to the side part of your
cap, starting at one end, going along
the bottom of the cap and ending at
the other end.
I use zigzag stitch because it will not
break when my surgeon pulls on
ends of his cap to tie the cap in the
back in a hurry

12. Use hot iron to fold the bottom of top part of your cap first
one time, then the second time to create a tube for elastic
band
Iron to fold one time Iron again to fold the second time

13. Use straight
stitch to
make a tube
for elastic
band

14. Cut 3 inches of elastic band and attach a safety pin to
one end of it – next step is to secure elastic band inside
the tube of fabric

15. Stick elastic band (safety pin first) into the
fabric tube and move it toward the other
end. When the end of elastic will align with
end of your fabric tube, secure it with a pin
When your safety pin is
out of the fabric tube and
the second end of elastic
band aligns with the end
of fabric tube, secure
elastic band with a pin
Once both edges of your
elastic band are secured with
pins, remove safety pin

16. Fold the top
of your cap
part in two
length wise,
find the
middle and
mark it with
a pin
Then fold
the side
part of your
cap in two
width wise,
find the
middle and
mark it with
a pin

17. Put the top of cap part and the side of cap part together face to face and align
the middle pins. Pin top part and side parts of your cap together in that point.

18. With side part of your cap being on top, pin it to the top part
of your cap. Pins should be ¾ of an inch apart.

19. Use straight
stitch ¼ inch
from the
fabric edge to
connect the
top part of
your cap and
the side part
together –
side part is on
top. Pull pins
out before
they reach
the needle.
Use your
fingers to hold
fabric in place
and together.

20. When you finish
the straight
stitch, flip the
cap over,
change settings
to zigzag and
stitch around
the top of hat –
keep your
needle on the
fabric

21. Do zigzag stitch
all the way
around the
connection of
top and side
parts of the
cap.

22. When you finish zigzag stitch, tie the ends of your threads
into a knot and hide the tails into a seam using a hand
needle – that’s how I do it.

23. Use hot iron to iron the seam toward the side part of
your cap

24. Starting at elastic band, make a decorative finishing stitch along
the seam which connects top part of the cap to the side part of
your cap.

25. Congratulations! This is your finished cap – this is how
the back of your cap looks with ends tied together.

26. This is how my cap looks in the front.
This cap is for sale – message me in
comments.