
It’s been years since my last needlepoint project (a belt for a boyfriend … who was an ex-boyfriend before the belt was done), and I wasn’t very good then. I’m worse now – but just competent enough to sew a patch onto a hat. In the video below, I tacked the corners down…but I recommend, after sewing on a second patch at home, that you instead use four pins to keep the patch in place as you stitch the edges. That means just a little less sewing.
Oh – and I also recommend having pliers at the ready – especially if you have even a touch of the ol’ arthritis. The patch material is stiff and thick, and the hat is thick at the seams thanks to the cotton reinforcement tape. The pliers make it a lot easier to pull the needle through.

I often use pliers for hand sewing leather. It works great!
I was curious because my 20something son asked me how to do this and I chuckled. In the end he found the task, as I showed him, to be easy. The difficulty was he owned no thread nor pins/needles.
Instead of fabric glue you could use basting tape, a kind of double sided tape for fabric.
Sure, but it might not hold up as well through brow sweat and washings.