HAT SUPPLIES:

• ½ Yard of fabric
  
• Hair comb (keeps the hat in place)
  
• 1 Yard of ribbon or cord
  
• Craft glue (Elmer’s or similar)
  
• Hot melt glue stick
  
• Large empty salt container (I found this be the best type of container to use - trust me!)
  
• Adornments: Feathers, ribbon, tulle, flowers, lace, etc.

TOOLS:

• Hot melt glue gun
  
• Scissors
  
• Sharp utility knife
  
• Sharp serrated knife
  
• Rotary cutter (Or sharp fabric scissors)
  
• Pencil
  
• Popsicle stick (for smearing glue)
  
• Fabric pen
  
• Twine, pushpin, & a key ring (Or something to make perfect circles with!)
  
• A Large surface to cut on, like a rotary cutting mat

STEP-BY-STEP GUIDE:

Step 1 – Hat top
Cut your salt container into two pieces with the serrated knife.

(I used to use drink bottles for these little hats, but I now use large salt containers. They have both a flat bottom and top, and it you cut it perfectly in half, you can make TWO hats! )

Step 2 – Hat Brim
For the size of hat we are making here, the brim should be around 7” diameter.

1. To make a perfect 7” circle for the brim, measure out half that much (3.5”), using a piece of cord and a key ring.

2. Place a stickpin through the knot that you made in the cord. This is the center of your circle. Then, while placing your pencil in the ring, pull the cord taut while drawing a circle.

3. Next, cut out your hat brim very carefully, using a sharp utility knife. Please note that is very important that you follow the line precisely, so that you have a smooth, even edge for your brim.

Step 3 – Cutting the material for the flat surfaces of the hat

First you will need to trace three circles in your material with your fabric pen. You will trace the outline of the hat’s top once, and the brim of the hat twice.Be very careful not to stretch or warp your fabric as you trace the cardboard. These circles need to be as smooth and symmetrical as possible.

Step 4 – Cutting the material for the curved side of the hat

Next, you will need to cut the material for the side of the hat’s top. You will need enough fabric to wrap around the sides of the hat, as well as enough to tuck up into the inside.

1. To do this, measure the circumference and the height of the hat’s top. In this case, it was 10.5” circumference, and 2.75” tall.

2. Then, add .5” seam allowance for the width. Add an inch to the height and double that number.

3. This means you should be cutting out a rectangle of fabric that is 11” x 7.5”. Be very careful to make the lines as straight and even as possible.

Step 5 – Gluing the fabric to the flat pieces of the hat.

Roll your 3 circles of material into little fabric “burritos”. This will allow you to place the material onto the glue-covered cardboard, smoothly and evenly.

1. For each flat side of the cardboard, you will want to cover it with white craft glue. Spread the glue over the entire surface (including edges!) with the popsicle stick. You don’t want the glue to be too thick, so feel free to use the stick to remove some glue if there is too much.

2. Begin by lining up the fabric flush with the cardboard edge. As you unroll your fabric over the cardboard, be careful that the edges are lining up, and you are smoothing the wrinkles out as you go.

3. Continue this with the other side of the large piece of cardboard, as well as for the top of the hat.

4. Sometimes the fabric stretches slightly as you apply it to the cardboard. If there is any overhanging fabric on the brim, trim it so that it comes flush with the edge of the cardboard. However if the fabric has stretched on the top of the hat, simply press and smooth it down over the edges.

Step 5 – Gluing the fabric to the curved part of the hat.

Apply hot melt glue to the curved edge of the hat near the top, while slowly rolling the 11” x 7.5” piece of fabric around it.

1. Once you have completely gone around the hat, place another strip of hot melt glue down the entire length of the topside of the inner edge of the fabric. You want a complete sealed “tube” of fabric, which is attached to the top of the hat’s edge.

2. Next, place some hot melt glue inside the hat top, and tuck the extra part of the fabric “tube” so that now the inner part of the hat is lined.

Step 6 – Drying the pieces

You will need to dry your pieces over night before proceeding to the next step. (It’s possible to skip this step during a costume emergency, but I don’t recommend it. The fabric cuts much better when it is not soaked with wet craft glue.)

Step 7 – Cutting your hat brim, finishing the edge, and attaching hat top

Place hat top in the center of the brim, and trace a line on it using the top as the guide.

1. Cut the hole out using a utility knife. Be very careful to cut directly on the line that you made, so not to make the hole too large or too small.

2. You can now trim down the hole remnant, and place it into the inside of the top of the hat. Use hot melt glue to adhere.

3. Apply a long line of hot melt glue to a matching narrow ribbon (about .25” usually works), and slowly roll the edge of the brim along it. Make sure you are applying the ribbon straight.

4. Push the top of the hat through the hole that you made in the brim, leaving about only .25” of the hat top on the other side.

5. Attach the brim to the top of the hat, by running a thick (but not too gooey!), hot melt glue band around.

Step 8 – Finishing

Cover the unsightly hot melt glue by running another (thin) band of glue around the edge, and attaching a matching cord or ribbon.

1. While you are under there, also attach a comb to the back of the hat (pay attention to where your seam is!), as well as attach two 1.5 foot ribbons on the inside of each side, so that you can secure the hat around your head.

2. Cover that ugly seam at the top of the hat by running a matching cord around the upper edge, using hot melt glue. You can also add a ribbon or two if you wish. Don’t forget to match up seams to be at the back to the hat!

3. Finally, adorn the hat as you wish. I wrapped some elegant holly around this particular hat, for a final touch of flair!

ADDITIONAL RESOURCES:
Imagi Knit (knitting & felting supplies)
General Bead (HUGE stock of jewelry-making supplies)

See Fahrion’s creations in person at the upcoming Bazaar Bizarre:
Saturday, December 15,11:00 a.m. - 6:00 p.m., $1
San Francisco County Fair Building
Golden Gate Park, San Francisco
www.bazaarbizarre.org/sanfrancisco.html