DIY Hooded Towel Poncho Sewing Tutorial - Quick and Easy Beginner Sewing Project

Tutorial and photos by Holly Hetzner

Hooded towel ponchos are the ultimate blend of comfort and functionality, perfect for beach days, poolside lounging, or simply cozying up after a bath. They make fantastic baby shower gifts and birthday gifts too - and all you need are towels!

My girls love to swim, and you can find us most days of the summer at our community pool. They love tossing on their hooded towel ponchos as a quick cover-up for the sun or on on their way to the snack shack! When they outgrew their favorite towel ponchos, I knew I had to make new ones! 

In this tutorial, we'll guide you step-by-step through creating your own hooded towel poncho. With just a few materials and simple sewing techniques, you'll craft a stylish and practical accessory that's ideal for both kids and adults. Get ready to combine creativity and comfort with this fun DIY project!

 

*Cost-saving tip! Check out sale areas of big box stores! You can find out-of-season or discontinued towels at great prices!

So let's get started!

Materials Needed:

    • 1 bath or swim towel
    • 1 hand towel
    • Matching thread
    • Scissors
    • Pins
    • Embroidery needle
    • Sewing machine
    • Measuring tape
    • Fabric marker or chalk

Sewing Machine Set-Up Instructions

Before diving into the project, it's important to set up your sewing machine correctly to handle the thickness and texture of towels.

1. Choose the Right Needle:

Use a size 90/14 or 100/16 needle, which is strong enough to sew through thick, absorbent towel fabric without breaking.

    2. Select the Appropriate Thread:

    Use polyester thread for its strength and durability, which is ideal for sewing heavy fabrics like towels.

      3. Adjust the Stitch Length:

      Set your machine to a longer stitch length, around 3.0 to 4.0 mm. This helps prevent the stitches from becoming too tight and pulling on the towel fabric.

        4. Use a Walking Foot:

        If available, attach a walking foot to your machine. This foot helps feed the thick layers of fabric evenly through the machine, preventing puckering and shifting.

          5. Adjust the Tension:

          Depending on your machine, you might need to slightly increase the upper thread tension to accommodate the thickness of the towel fabric. Test on a scrap piece of towel first.

            6. Test Your Settings:

            Sew a few test stitches on a scrap piece of towel to ensure your machine settings are correct. Adjust as necessary for smooth, even stitches.

              Can you hand-sew this project? Absolutely! We'll note hand-sewing instructions in the tutorial! 

              Step-By-Step Instructions

              1. Preparing the Towels

              • Large Bath Towel: This will be the body of your poncho.
              • Hand Towel: This will be used to create the hood.
                • Wash and dry your towels. Remove any tags on the hand towel. 

                2. Sewing the Hood

                  • Fold the hand towel in half with the wrong sides together so that the shorter edges meet.
                  • Sew along one of the shorter edges with a straight stitch and 1/4-inch seam allowance.
                    • If hand-sewing, use your embroidery needle to back-stitch, also with a 1/4" seam allowance. Consider using two pieces of thread to create a stronger seam!
                  • Turn right side out and lay flat.  
                  • Measure the width of your hood. (In my example, the width of my hood is approximately 12 inches.)
                  • Your hood now has two ends. Choose which end will be at your forehead and which will be at your neck. 

                3. Tacking Down the Bound Edge of the Hood

                If your hand towel includes a bound edge, you may want to sew the ends of the towel where they would meet at your forehead to create a more finished look.
                  • With the hood right sides out, pin or hold the bound edges together, with one edge slightly overlapping the other.
                  • With an embroidery needle and matching thread, sew a few stitches to tack the edges together, securing them in place. I used a whip stitch to keep my edges secure and flat!
                  • Set the hood aside. 

                4. Preparing the Poncho

                  • Fold your large towel in half with the right sides together so that the shorter edges meet.
                  • Using your measuring tape or ruler, measure the length of the folded towel along the top edge.
                  • Find the center point and mark it with chalk or a fabric marker. (If your towel measures approximately 26 inches wide, your center point would be at 13 inches.)
                  • Find your measurement of the width of the hood from Step 2.
                  • From the center point, measure down the 1/2 the width of the hood and mark it with chalk or a fabric marker. (If your hand towel has a width of 12 inches, measure 6 inches from the center point.)
                  • With your scissors, cut from the center point mark to the second mark.

                5. Pinning the Hood to the Poncho

                  • Open the large towel, right side up.
                  • Locate the top of the slit. Pin the center of the bottom edge of the hand towel to the top of the slit. Pin the left edge to the bottom of the slit. Repeat on the right edge. Add more pins as needed.

                  6. Sewing the Hood

                   

                  7. Final Touches

                    • Trim any loose threads.
                    • Try on the poncho to ensure the fit is comfortable and make any necessary adjustments.

                  Your hooded towel poncho is now ready to use! Perfect for beach days, poolside lounging, or cozying up after a bath!

                   

                  If you make this hooded towel poncho and love it, let us know! Post on Instagram with #coppercreekpatternshoodedtowelponcho, or post a pic on our FB Community page!

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