How to Make a Stovepipe Hat

Lincoln's stovepipe hat, beard, black tailored trousers and long frock coat have been stuck in the minds of millions. This look was typical for gentlemen of the late Victorian Era. Here is how to make your own stovepipe hat.

Instructions

Difficulty: Easy

Things You’ll Need:

• 3 sheets of black felt
• 3 sheets of shirt cardboard, cut to fit the felt
• 8-inch diameter paper plate
• 10-inch diameter paper plate
• Hot melt glue gun
• Clear hot melt glue sticks
• Wall sizing
• Water
• Painter's tray

1. Using the paper plate, cut a circle on one piece of shirt cardboard. Using this as a template, cut a circle of black felt. Cut a second circle of black felt using the 10-inch diameter plate.
2. Mix wall sizing with water in a painter's tray to make a thin mixture. Soak all three felt pieces in wall sizing.
3. Roll a sheet of shirt cardboard into a tube with an 8-inch diameter. Secure with hot melt glue and let the glue set. Use the 8-inch circle of shirt cardboard as the top of your hat by gluing it to the cardboard tube you have made.
4. Squeeze excess wall sizing from each piece of felt. Spread the 8-inch piece of felt on top of the cardboard hat mold. Spread the felt rectangle around the diameter of the cardboard tube portion of hat mold. Allow to dry.
5. After the felt has dried, attach felted brim cardboard to the bottom of the cardboard "hat" mold you are making. Pipe clear hot melt glue around the brim to secure. Wearing rubber finger protectors or rubber gloves to protect your hands, spread the glue carefully.
6. Trim inside the hat to fit your head, cutting a small hole with scissors first, then trimming to the inside of the cardboard tube.

Tips & Warnings

• To make a waterproof version of this hat, paint it with clear acrylic.
• Be careful to use good ventilation if you paint your hat with clear acrylic. If you can smell fumes, you do not have adequate ventilation.

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