This project didn't cost me anything because
I already had all of the supplies.
Supplies
Step 1
Cut a piece of cardboard big enough to wrap around your head. Now I know everyone says don't use corrugated cardboard, but it was all I had, so I just made sure I creased it in a lot of places so it was more rounded.
Now this piece measured a little over 8 inches, but by the end I had trimmed it so it only measured a little over 4 1/2 inches. But the height is totally up to you and what you want.
Step 2
Once I had glued the ends together, I cut a slight arch into both sides, this will give the brim a bit of a curve, and make the hat less flat. Also I had cut these tabs, but please ignore them, I ended up cutting them off.
Step 3
Next I took my cereal box, and traced out the brim shape, making sure to trace inside the hat as well.
I also cut tabs into the brim, these I will be keeping. I will glue them to the inside of the hat.
Step 4
Next I glued the brim to the top, I also added a layer of posterboard, simply because the brim felt a bit too thin for me.
This is what it looks like from the side, see the nice curve the arches gave us.
Step 5
Next it's time to finish up the construction part of the hat. I traced the top of the hat onto our thick cardboard, and once cut out, glued it into place.
Step 6
I then painted the whole hat black, this is optional though. I was using think fabric so I was afraid the cardboard might show through. But if you are using thicker fabric, you can skip this step.
Step 7
Now comes the fabric. Now I glued all this on with tacky glue, because I felt like I could get a smoother surface with it, where as hot glue might have left bumps. First I glued down the top part of the hat.
Then only using hot glue at the edges, I glued the very top of the sides along the edge of the top of the hat.
Then I glued the underside of the brim, folding the fabric both inside the hat, and on top of the brim.
Then I glued the fabric to the top of the brim, using hot glue on the edges like I did the sides of the hat. And also gluing the extra fabric up the sides.
And lastly I glued the sides down, hiding any extra fabric that needed to be hidden.
I also went ahead and painted the inside of the hat as well.