What You'll Make and What You Need

A bandana headband is a triangle of fabric folded and sewn into a band that ties at the back of your head. You can make one from a square bandana, a piece of quilting cotton, or any medium-weight fabric about 20 inches square. The finished headband takes roughly 30 minutes from cutting to the final stitch, and you need only a needle, thread, scissors, and a sewing machine or needle and thread for hand sewing.

The headband works because the fold creates a sturdy edge without binding, and the tie ends let you adjust the fit. Once you've made one, you can repeat the same steps with different fabrics in under an hour each time.

Key Takeaways

  • Start with a square piece of fabric roughly 20 inches on each side, or use a standard bandana without modification.
  • Fold the square diagonally in half to make a triangle, then fold the long edge inward by half an inch and sew it down to create a finished edge.
  • Fold the triangle in half lengthwise so the sewn edge is on the outside, then sew the two short ends closed to form the tie ends.
  • Turn the headband right-side out through one of the tie ends, then hand-stitch the opening closed with a ladder stitch for an invisible seam.
  • Press the finished headband with an iron to flatten the seams and give it a polished look.

Cutting and Preparing Your Fabric

If you're starting with a square of fabric, cut it to 20 inches by 20 inches. A standard bandana is already the right size, so you can skip cutting. Lay the square flat on your work surface with the right side (the printed or nicer side) facing up.

Fold the square diagonally so the top-right corner meets the bottom-left corner. Press the fold with your hand or iron to crease it. You now have a triangle with the fold on one side and two raw edges on the other two sides. The fold will become the front of your headband, and the raw edges will be sewn and turned inside.

Sewing the Long Edge

The long edge of the triangle (the folded side) needs a finished edge so it won't fray. Fold that long edge inward by half an inch, with the fold facing you. Press it flat with your iron or your fingers. This creates a narrow hem that will show on the outside of the finished headband.

Sew along this folded edge using a straight stitch, staying about one-eighth inch from the fold. If you're using a sewing machine, use a medium stitch length (around 2.5) and thread that matches your fabric. If you're hand-sewing, use a running stitch with stitches about one-eighth inch apart. Backstitch at the start and end to lock the thread. This seam will be visible on the front of the headband, so keep it straight and even.

Folding and Sewing the Tie Ends

Fold the triangle in half lengthwise, bringing the two short raw edges together. The sewn long edge should now be on the outside of the fold. Pin the two short ends together if you're using a machine, or hold them steady if you're hand-sewing.

Sew across each short end with a straight stitch, about one-quarter inch from the edge. Sew one end completely, then pivot and sew the other end. These seams create the two tie ends of the headband. Leave the long folded edge open—that's where you'll turn the headband right-side out. Backstitch at the start and end of each seam to prevent unraveling.

Turning and Closing the Headband

Reach into one of the open tie ends and grab the opposite tie end from the inside. Pull gently to turn the entire headband right-side out. The sewn long edge is now on the outside where you want it, and the raw seams are hidden inside. The opening at the long edge is now a gap between the two layers of fabric.

Close this gap with a ladder stitch, also called an invisible stitch. Thread a needle with thread that matches your fabric. Bring the needle up through the fold of one side of the opening, then across to the opposite side and down into the fold there. Slide the needle inside the fold for about one-quarter inch, then come back out and cross to the other side. Repeat this back-and-forth motion along the entire opening. After every inch or so, gently pull the thread to close the gap. When you reach the end, tie off the thread inside the fold so the knot is hidden.

Pressing and Finishing

Lay the headband flat and press it with a warm iron to flatten all the seams. Pay special attention to the long edge where the hem is visible—a crisp press makes the headband look finished and professional. Press the tie ends flat as well so they lie smoothly when you tie them.

Try the headband on by placing it across your forehead with the sewn edge facing forward, then tie the two ends at the back of your head. If the fit is too loose or too tight, you can adjust by tying the ends differently or, if needed, by taking in or letting out the seams at the tie ends. Once the fit is right, your headband is ready to wear.

Common Mistakes to Avoid

The most common mistake is sewing the tie ends with the wrong side of the fabric facing out. Before you sew, double-check that the sewn long edge is on the outside of the fold. If you sew with the wrong side out, you'll have to unpick the seams and start over.

Another frequent error is making the hem on the long edge too wide. A half-inch fold is enough; anything wider makes the headband bulky and hard to tie comfortably. Also, don't skip the pressing step. A pressed headband looks intentional and holds its shape better when you wear it.

If your ladder stitch isn't invisible, you're likely pulling the thread too tight too soon. Close the gap gradually as you stitch, and only pull hard enough to bring the edges together—not so hard that you pucker the fabric.

Frequently Asked Questions

Can I use a knit fabric instead of cotton?

Knits work but are trickier because they stretch and curl at the edges. If you want to try one, use a ballpoint needle on your machine (or a ballpoint hand-sewing needle) to avoid snagging the fibers. You may also want to use a narrow zigzag stitch instead of a straight stitch to let the fabric stretch without breaking the thread.

What if I don't have a sewing machine?

Hand-sewing works perfectly for this project. Use a running stitch for all the seams and a ladder stitch to close the opening. Hand-sewing takes longer—roughly 45 minutes to an hour—but the steps are identical. Make sure your stitches are small and even so the seams are strong.

How do I make the headband wider or narrower?

Start with a larger or smaller square of fabric. A 24-inch square makes a wider headband; a 16-inch square makes a narrower one. The sewing steps stay the same, but a larger square will take slightly longer to sew because the seams are longer.

Can I add elastic instead of tie ends?

Yes. Instead of sewing the two short ends closed, insert a piece of elastic (about 6 inches long) between the layers at one end before you sew it shut. Sew across that end with the elastic sandwiched inside, then sew the other end closed without elastic. When you turn it right-side out, the elastic will be hidden inside and will hold the headband in place without tying.

What thread color should I use?

Match the thread to your fabric as closely as you can. If your fabric is a solid color, use thread in that same color. If your fabric is patterned, use a color that blends with the dominant color. Mismatched thread is visible on the outside seams and looks unfinished.